US20070227993A1

US20070227993A1 - Modular shelving and method for its use

Info

Publication number: US20070227993A1
Application number: US11/395,606
Authority: US
Inventors: Stephen Wilkinson
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-03-30
Filing date: 2006-03-30
Publication date: 2007-10-04

Abstract

The present invention is comprised of modular shelving, which is further comprised of modules and horizontal planks or shelves. Each module is generally comprised of an exterior shell that may be in the form of a wide variety of different shapes. Each module is preferably comprised of a molded polymer exterior shell. The interior volume of the module may be filled with a semi-rigid or rigid foam material or other structural members or materials to provide additional support for the horizontal planks. Each module also has at least one channel that passes through the module. Each channel is of a size and shape adapted to receive and hold one of the horizontal planks. It is also possible to stack the modules of the modular shelving upon one another. The present invention also includes a method of assembling the modular shelving.

Description

BACKGROUND

The present invention generally relates to modular shelving, and more specifically to modular shelving comprised of modules, which typically are oriented vertically, and horizontal planks that are supported by the modules, all as described in more detail below. In addition, the present invention includes a method of assembling and using the modular shelving.
Fully assembled shelving units are well known in the art. These fully assembled units typically have vertical components, such as wooden or plastic sheets, supporting horizontally oriented components, which are typically referred to as “shelves.” The consumer can place items, such as books, knick-knacks, supplies and almost any other items of proper size on the shelves. These fully assembled shelving units, however, have several disadvantages. For example, they are often large and bulky. They are also often heavy and therefore cannot be easily moved. In addition, fully assembled shelving units do not typically have the flexibility to adapt to changing uses and conditions. For example, a unit that measures 60 inches high may not generally be positioned against a wall with a window having its bottom edge only three feet above the floor without blocking the view out the window. To preserve the view, it is necessary to purchase a new shelving unit that measures no more than 36 inches in its vertical dimension. Also, because the vertical sheets are typically constructed of rigid materials, if a person, and in particular, a child, inadvertently falls against the sheets, the person may be injured as a result of the contact with the rigid surface. Further, these shelving units often have relatively sharp corners at the exterior joints between the shelves and the vertical sheets. Again, a person inadvertently falling against a corner of this type is likely to suffer an injury as a result of contacting the rigid corner during the fall. These types of shelving units are also often relatively expensive. Finally, these shelving units are often plain, in the sense that they do not typically have aesthetic features that may be desired by the users of the units. For example, it may be desirable to have shelving units that incorporate cartoon characters for use in a child's bedroom or nursery.
There are also shelving units known in the relevant art that may be disassembled. These shelving units also often suffer from various disadvantages. For example, they are often comprised of many parts and connectors, so that they are difficult and time consuming to assemble and disassemble. In addition, they are also often inflexible in their finished form, so that the fully assembled unit is not adaptable to multiple uses. They also typically lack unique aesthetic features that may be desired by the users of the units. Although some of these shelving units may also be somewhat modular in structure or have other features making them somewhat more flexible, these modular units also suffer from disadvantages. For example, they may also be comprised of heavy and bulky components, which make them difficult to move. In addition, they are typically constructed of rigid materials so that a person falling against their vertical components may suffer injury as a result. They also often have sharp corners that may produce injuries where a person falls against a corner. Further, they are often constructed from components that are not very structurally sound, so that they suffer from excessive movement (wobbling) in use or are limited in the weight they can support. Further still, they are often limited in that only complimentary components that are a part of an entire system may be used in conjunction with the particular unit. For example, it is often not practical to substitute a less expensive component (such as a wooden board) as a part of the modularized shelving unit because only the shelves and the vertical sheets that comprise the overall system may practically be used in constructing the particular shelving unit. This may make the shelving unit too expensive for some consumers with a limited budget. Thus, these consumers may end up constructing “modular units” of their own from cinderblocks and wooden boards or other similar types of materials. These homemade units, however, suffer from the same disadvantages described above and may be especially dangerous for use where small children are present.
There is therefore a need for modular shelving that is lightweight and easy to move and store. It also needs to be easy to assemble and disassemble. In addition, there is a need for modular shelving that provides adequate structural integrity to support the anticipated loading on the shelving unit. There is also a need for modular shelving that can incorporate unique aesthetic features that may be desired by the users of the shelving. The modular shelving also needs to be flexible enough to allow less expensive components that are not a part of the overall modular system to be incorporated into the shelving unit. For example, the shelving should allow for the use of wooden boards that may not be perfectly flat (i.e., slightly warped). Similarly, the modular shelving needs to be inexpensive to manufacture so that users with a limited budget are capable of purchasing the shelving. Further, there is a need for modular shelving that is flexible in its use, such that it can be utilized with different numbers of shelves, different lengths of shelves, and multiple numbers of vertical supports in order to modify the weight bearing capacity of the shelving. Further still, there is a need for modular shelving that has vertical supports that are resilient enough to provide adequate support for the shelves, while also having characteristics that mitigate the potential for injury in cases where a person falls against a vertical support. This is especially true for modular shelving that is used in areas where small children may be present.

SUMMARY

The present invention is directed to modular shelving and a method for its use that meets the needs discussed above in the Background section. As described in greater detail below, the present invention, when used for its intended purposes, has many advantages over other devices known in the art, as well as novel features that result in new modular shelving and new methods for its use that are not anticipated, rendered obvious, suggested, or even implied by any prior art devices or methods, either alone or in any combination thereof.
In a first version, the present invention is comprised of a module for use in modular shelving. In this version, the module is comprised of an exterior shell, which is further comprised of a rigid material. The exterior shell has an ornamental or functional shape with a bottom surface. At least a portion of the bottom surface rests on a support surface. The exterior shell also has at least one channel positioned therein. The at least one channel is of a size and orientation adapted to receive and hold at least one horizontal plank, which is supported by the module in an orientation approximately horizontal to the support surface while the at least one horizontal plank is positioned within the at least one channel. The at least one channel may be an interior channel that is approximately rectangular in shape or that is approximately rectangular in shape with a slightly concave upper surface. In some embodiments of this version, the module is further comprised of a top surface approximately opposite the bottom surface. A top channel may be positioned in the top surface. In addition, the top channel is approximately rectangular in shape and is of a size and orientation adapted to receive and hold a top horizontal plank. The top horizontal plank is supported by the module in an orientation approximately horizontal to the support surface while the top horizontal plank is positioned within the top channel. The top horizontal plank and the at least one horizontal plank may each extend from the module in a different direction while the top horizontal plank is positioned in the top channel and the at least one horizontal plank is positioned in the at least one interior channel. Further, the rigid material comprising the exterior shell may be comprised of a rigid polymer material, and the exterior shell may have a preferred thickness in the range from ⅛ inches to 3/16 inches. In some embodiments, the module may further comprise internal support means, as described in more detail below, to provide additional support for the at least one horizontal plank. The internal support means may be comprised of at least one structural member extending between various points on the interior surfaces of the exterior shell and the surfaces of the at least one channel. In addition, the interior volume bounded by the exterior shell may have a rigid foam material positioned therein. In yet other embodiments, the module may further comprise at least one support bracket. The at least one support bracket is positioned in the at least one channel and extends outward from the exterior shell along the longitudinal axis of the at least one horizontal plank to provide additional support for the at least one horizontal plank.
In a second version, the module is comprised of an exterior shell, which is further comprised of a flexible or semi-rigid material, and a rigid foam material positioned within the interior volume bounded by the exterior shell. The exterior shell has an ornamental or functional shape and a bottom surface. At least a portion of the bottom surface rests on a support surface. The exterior shell also has at least one channel positioned therein. The at least one channel is of a size and orientation adapted to receive and hold at least one horizontal plank in an orientation approximately horizontal to the support surface. The at least one horizontal plank is supported by the module in an orientation approximately horizontal to the support surface while the at least one horizontal plank is positioned within the at least one channel. The flexible or semi-rigid material of the exterior shell may be comprised of a flexible or semi-rigid polymer material, and the exterior shell may have a preferred thickness in the range from 1/16 inches to 3/16 inches. In some embodiments, the polymer material may be molded polyethylene. The module may also further comprise internal support means, as described in more detail below, to provide additional support for the at least one horizontal plank. Otherwise, the module of this second version may have substantially the same structure, features and characteristics as the first version of the module described above.
In a third version, the present invention is a modular shelving system comprised of at least one first module, at least one second module, and at least one horizontal plank. The at least one first module is comprised of a flexible or semi-rigid exterior shell and a rigid foam material positioned within the interior volume bounded by the exterior shell. The exterior shell has an ornamental or functional shape and a bottom surface. At least a portion of the bottom surface rests on a support surface. The at least one second module is comprised of an exterior shell having an ornamental or functional shape and a bottom surface. At least a portion of this bottom surface also rests on the support surface. The at least one first module and the at least one second module each have at least one channel having a rectangular bottom portion positioned therein. The at least one channel is of a size and orientation adapted to receive and hold a portion of the at least one horizontal plank. The at least one horizontal plank is supported by the at least one first module and the at least one second module in an orientation approximately horizontal to the support surface while the at least one horizontal plank is positioned within the at least one channel of the at least one first module and the at least one channel of the at least one second module. Generally, the at least one first module may have any of the characteristics described above with respect to the module of the second version of the present invention The at least one second module may generally have any of the characteristics described above with respect to the modules of the first version or the second version of the present invention. In embodiments where the at least one first module is further comprised of a top surface having a top channel positioned therein, a portion of the top horizontal plank positioned in the top channel is also positioned within one of the at least one channels of the at least one second module. The top horizontal plank is supported by the at least one first module and the at least one second module in an orientation approximately horizontal to the support surface.
In a fourth version, the present invention is also a modular shelving system comprised of at least one first module, at least one second module, and at least one horizontal plank. In this version, however, the at least one first module is comprised of a rigid exterior shell having an ornamental or functional shape and a bottom surface. At least a portion of the bottom surface rests on a support surface. The at least one second module is comprised of an exterior shell having an ornamental or functional shape and a bottom surface. At least a portion of this bottom surface also rests on the support surface. The at least one first module and the at least one second module each have at least one channel having a rectangular bottom portion positioned therein. The at least one channel is of a size and orientation adapted to receive and hold a portion of the at least one horizontal plank. The at least one horizontal plank is supported by the at least one first module and the at least one second module in an orientation approximately horizontal to the support surface while the at least one horizontal plank is positioned within the at least one channel of the at least one first module and the at least one channel of the at least one second module. Generally, the at least one first module may have any of the characteristics described above with respect to the module of the first version of the present invention The at least one second module may generally have any of the characteristics described above with respect to the modules of the first version or the second version of the present invention. Otherwise, the modular shelving system of this fourth version may have substantially the same structure, features and characteristics as the third version of the present invention described above.
The present invention also includes a method for assembling the modular shelving system. Generally, the method comprises the following actions. First, a predetermined number of the at least two modules are positioned on the support surface in a predetermined orientation for the modular shelving. Next, at least one horizontal plank is placed in a predetermined position in the at least one channel of each of the at least two modules, as described in more detail below.
As described in more detail below, the modular shelving of the present invention successfully meets the requirements described in the Background section above. For example, in its preferred embodiments, the modular shelving is lightweight and easy to move and store. It is also easy to assemble and disassemble. For example, the horizontal planks can be easily removed from the modules and can be stacked to conserve space. In addition, in many embodiments, the modules can also be stacked in a manner that conserves space. As described in more detail below, the modular shelving also provides adequate structural integrity to support the anticipated loading on typical shelving units. Further, the modules of the modular shelving can incorporate almost any functional or ornamental shape. Thus, the modular shelving can take on many unique aesthetic features to accommodate the tastes of users of the shelving. The modular shelving is also flexible enough to allow less expensive components that are not a part of the overall modular system to be incorporated into the shelving unit. For example, the shelving allows for the use of wooden boards that may not be perfectly flat (i.e., slightly warped). In many of its embodiments, the modular shelving should also be inexpensive to manufacture, allowing users with a limited budget to purchase the shelving. Further, the modular shelving is flexible in its use. For example, it can be utilized with different numbers of shelves, different lengths of shelves, different orientations of shelves, and different numbers of modules in order to modify the weight bearing capacity of the shelving or accommodate the aesthetic tastes of the user, or both. In their preferred embodiments, the modules of the modular shelving are resilient enough to provide adequate support for the shelves, while also having characteristics that mitigate the potential for injury in cases where a person falls against a module. For example, the foam interior within the exterior shell of molded polyethylene (or other suitable flexible or semi-rigid material) is able to deform and spread the loading of the impact in the case of a fall. In addition, the modules preferably have rounded exterior edges. These features make the modular shelving particularly advantageous for use in areas where small children may be present.
There has thus been outlined, rather broadly, the more primary features of the present invention. There are additional features that are also included in the various embodiments of the invention that are described hereinafter and that form the subject matter of the claims appended hereto. In this respect, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the following drawing. This invention may be embodied in the form illustrated in the accompanying drawings, but the drawings are illustrative only and changes may be made in the specific construction illustrated and described within the scope of the appended claims. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following description, will be better understood when read in conjunction with the following appended drawings:
FIG. 1, which is a perspective view of an embodiment of the modular shelving of the present invention from above and to the side of the modular shelving;
FIG. 2, which is an elevation view of a side surface of a module of the embodiment of the modular shelving illustrated in FIG. 1;
FIG. 3, which is an elevation view of an end surface of the module illustrated in FIG. 2, as viewed along the line 3-3 of FIG. 2;
FIG. 4, which is a plan view of the bottom surface of the module illustrated in FIG. 2, as viewed along the line 4-4 of FIG. 2;
FIG. 5, which is an enlarged, detail, elevation view of a portion of the upper interior channel of the module illustrated in FIG. 2;
FIG. 6, which is a perspective view of another embodiment of a module of the present invention from above and to the side of the module;
FIG. 7A, which is a perspective view of another embodiment of a module of the present invention from above and to the side of the module;
FIG. 7B, which is a perspective view of an embodiment of a support bracket of the module illustrated in FIG. 7A, from above and to the side of the module;
FIG. 7C, which is a cross-sectional view of the top interior channel of the module illustrated in FIG. 7A;
FIG. 8, which is a perspective view of another embodiment of a module of the present invention from above and to the side of the module; and
FIG. 9, which is a perspective view of another embodiment of a module of the present invention from above and to the side of the module.

DETAILED DESCRIPTION

Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it is to be noted that the embodiments are not intended to limit the invention to those embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims.
One embodiment of the present invention is illustrated in FIG. 1. Generally, in this embodiment of the present invention, the modular shelving 10 is comprised of three modules 20, 30, 40 and three horizontal planks 51, 52, 53. The horizontal planks 51, 52, 53 are supported by the modules 20, 30, 40 in a manner so that the horizontal planks 51, 52, 53 are approximately parallel to a support surface 11 (which is not a part of the present invention), such as a floor, porch, deck, or other surface or structure. It is to be noted that references herein to the horizontal planks 51, 52, 53 being “approximately horizontal” to the support surface 11 are intended to mean that the horizontal planks 51, 52, 53 are oriented relative to the support surface 11 in the same manner that horizontal shelving members commonly known in the relevant art are typically oriented relative to the support surface 11 (floor, for example) so that utilitarian and ornamental articles and items may be placed on the shelving members. In some cases, the support surface 11 may not be perfectly horizontal over the length of the modular shelving 10 or may not be entirely flat over such length, as where the support surface 11 has contours such as depressions or humps between or under the modules 20, 30, 40. The present invention is intended to encompass the use of the modular shelving 10 in all such cases, as defined in the appended claims.
In the embodiment of the modular shelving 10 illustrated in FIG. 1, and referring to module 20 as an example, as illustrated in FIG. 1 and more particularly in FIG. 2 through FIG. 4, the module 20 is comprised of an approximately flat bottom surface 21 that rests on the support surface 11. The module 20 is also comprised of a top surface 22 that is approximately opposite the bottom surface 21, two opposing end surfaces 23, 24 bounded by the top surface 22 and the bottom surface 21, and two opposing side surfaces 25, 26 bounded by the two opposing end surfaces 23, 24, the top surface 22, and the bottom surface 21. It is to be noted, however, that in other embodiments of the present invention, the modules 20, 30, 40 may have almost any shape as long as they retain the structural integrity necessary to adequately support the expected loading on the horizontal planks 51, 52, 53, as described in more detail below. For example, and again using module 20 as an example, the module 20 may have an approximately uniform thickness, as would be the case if the width 23′ of the end surface 23 (and thickness 23′ of the module 20) were constant over its entire length, while the side surfaces 25, 26 may have a different shape. In these cases, the side surfaces 25, 26 may each be shaped approximately as a square, triangle, pentagon, hexagon, parallelogram, trapezoid, other polygon, circle, ellipse, parabola, swirl, another shape having one or more arcuate boundaries or linear boundaries or both, or combinations of such shapes. In addition, in these cases, the side surfaces 25, 26 may also be shaped as the silhouette of clouds, vehicles, animals, bells, cartoon characters, or many other objects and items or combinations of such shapes as may appeal to the aesthetic taste of the user of the modular shelving 10. For example, FIG. 6 illustrates another embodiment of the present invention wherein the module 120 has the approximate shape of a silhouette of a cloud. As another example, FIG. 7 illustrates another embodiment of the present invention wherein the module 220 has the approximate shape of a silhouette of a flower. And as another example, FIG. 8 illustrates another embodiment of the present invention wherein the module 320 is approximately triangular in shape. Referring again to FIG. 1 through FIG. 4, in other cases, the thickness 23′ of the module 20 may be variable, as would be the case where the width 23′ of the end surface 23 is not uniform over its entire length. In these cases, each of the end surfaces 23, 24, when viewed from above the end surface 23, 24, may be shaped approximately as a circle, an ellipse, a parabola, a triangle, a pentagon, a hexagon, other suitable polygons, an hourglass, another shape having one or more arcuate boundaries or linear boundaries or both, or combinations of such shapes, as long as the overall shape of the module 20 is such that it retains the structural integrity necessary to adequately support the expected loading on the horizontal planks 51, 52, 53, as described in more detail below. Also, in these cases, the side surfaces 25, 26 may generally have any of the shapes described above in the case where the width 23′ of the end surface 23 is uniform over the entire length of the end surface 23. It is also to be noted that the modules 20, 30, 40 may each be shaped as common (or uncommon) three-dimensional objects. For example, the module 20 may have the approximate shape of a bell, a pyramid, or many other objects and items or combinations of such shapes as may appeal to the aesthetic taste of the user of the modular shelving 10, as long as the overall shape of the module 20 is such that it retains the structural integrity necessary to adequately support the expected loading on the horizontal planks 51, 52, 53, as described in more detail below. It is not necessary that the module 20 be in the form of a “solid” figure. For example, as illustrated in FIG. 9, the module 420 may have two side surfaces 425, 426 that are relatively flat with a relatively thin piece having two end surfaces 423, 424 between them. It is also to be noted that different styles of modules 20, 30, 40 may be used in any particular unit of modular shelving 10. For example, and referring again to FIG. 1, the end module 20 may be in the shape and form illustrated in FIG. 1, while the central module 30 may have an approximately triangular shape, as in the case of the module 320 illustrated in FIG. 8, and the other end module 40 may be shaped as a silhouette of a cloud, as in the case of the module 120 illustrated in FIG. 6.
Generally, each module 20, 30, 40 must have the structural integrity necessary to adequately support the expected loading on the horizontal planks 51, 52, 53. As described in more detail below, in some embodiments the exterior shells of the modules 20, 20, 40 provide the primary means of support for the horizontal planks 51, 52, 53, while in other embodiments internal support means, such as rigid foam or other structural support members or materials, may be used to provide additional or primary support. The upper portion (the portion most distant from the support surface 11) of each module 20, 30, 40 is preferably approximately the same size as or smaller than the lower portion of the module 20, 30, 40 (the portion closest to the support surface 11). This provides the modular shelving 10 with stability so that it does not tend to lean or tip over when loading is placed on the horizontal planks 51, 52, 53. In addition, it is necessary to consider the number of modules 20, 30, 40 to be utilized in any particular unit of modular shelving 10 to determine its weight bearing capacity. For example, in the embodiment illustrated in FIG. 1, the modular shelving 10 is comprised of three modules 20, 30, 40. In other embodiments, the modular shelving 10 may be comprised of more or fewer modules 20, 30, 40, such as two modules or four modules. The preferred number of modules 20, 30, 40 to be utilized in any unit of modular shelving 10 is dependent upon a number of parameters, such as the length and width of the horizontal planks 51, 52, 53, the thickness of the horizontal planks 51, 52, 53, the load to be placed on the horizontal planks 51, 52, 53, and the individual taste of the user of the modular shelving 10. In addition, the preferred number of modules 20, 30, 40 to be used in any unit of modular shelving 10 is dependent upon the unique structural characteristics of the modules 20, 30, 40 themselves, as described in more detail below. Otherwise, the principles involved in providing structural stability and how to accommodate them in the design of the modules 20, 30, 40 are well known to those having skill in the relevant art, so that they are not described further herein.
Referring again to the embodiment of the modular shelving 10 illustrated in FIG. 1, and to the embodiment of the module 20 illustrated in FIG. 2 through FIG. 4 as an example, the module 20 has a top channel 27 disposed in the top surface 22 thereof. The top channel 27 is approximately rectangular in shape and has a size and orientation adapted to receive and support a top horizontal plank 51 in an orientation approximately horizontal to the support surface 11. The top channel 27 has two side surfaces 27 a, 27 b that are preferably situated perpendicular to the lower surface 27 c of the top channel 27. In the embodiment illustrated in FIG. 1, the sides 27 a, 27 b of the top channel 27 are approximately the same height as the thickness of the top horizontal plank 51, so that the top surface 51 a of the top approximately horizontal plank 51 is approximately flush with the top surface 22 of the module 20. Although this is the preferred effect in this embodiment, it is to be noted that in other embodiments the sides 27 a, 27 b of the top channel 27 may both be higher than the thickness (and top surface 51 a) of the top horizontal plank 51, or the sides 27 a, 27 b may both be lower than the thickness (and top surface 51 a) of the top horizontal plank 51, or one side 27 a or 27 b may be higher and the other side 27 b or 27 a lower, respectively, than the thickness (and top surface 51 a) of the top horizontal plank 51. For example, in the embodiment of the module 120 illustrated in FIG. 6, the sides 127 a, 127 b of the top channel 127 are both higher than the surface 151 a of the top horizontal plank 151. Referring again to the module 20 of FIG. 1 though FIG. 4 as an example, the lower surface 27 c of the top channel 27 is preferably approximately parallel to the support surface 11, so that the top horizontal plank 51 rests adjacent to the entire lower surface 27 c of the top channel 27 along the thickness 23′ of the module 20. In addition, this also allows the module 20 to support the top horizontal plank 51 in a manner so that the top horizontal plank 51 is approximately parallel to the support surface 11. Preferably, as illustrated in FIG. 1, the width 27 c′ of the lower surface 27 c of the top channel 27 is approximately the same as the width 51 b of the top horizontal plank 51, so that the sides 51 c, 51 d of the top horizontal plank 51 fit tightly against the sides 27 a, 27 b, respectively, of the top channel 27. It is not necessary, however, that this be the case in all embodiments. The preferred width 27 c′ of the top channel 27 and the preferred height of the sides 27 a, 27 b of the top channel 27 b are dependent upon a number of factors, such as the width 51 b and thickness of the top horizontal plank 51, the expected loading on the top horizontal plank 51, the unique structural characteristics of the module 20, and the individual taste of the user of the modular shelving 10. For example, in the embodiment illustrated in FIG. 1, the top horizontal plank 51 may be a standard wooden 1×12 plank (¾″×11½″), in which case the height of the sides 27 a, 27 b may each be approximately ¾ inches and the width 27 c′ of the top channel 27 may be approximately 11⅝ inches. It is to be noted that the horizontal planks 51, 52, 53 may each be comprised of almost any material or combination of materials that is suitable to support the expected loading on the horizontal planks 51, 52, 53. Such materials may include metal, glass, wood, pressboard, rigid polymers (such as polypropylene, polyethylene and polyvinyl chloride), paper, cardboard, fabric, cloth, fiberglass and carbon composites, resins, minerals, other artificial and naturally occurring materials, or combinations of such materials. In addition, each of the horizontal planks 51, 52, 53 may actually be a composite of more than one plank. For example, in order to produce an increased weight bearing capacity and an aesthetically pleasing look to some users of the modular shelving 10, the top horizontal plank 51 may be a series of four standard 2×4 (1½″×3½″) wooden planks laid side-by-side, producing a top horizontal plank having an overall thickness of approximately 1½ inches and an overall width of approximately 14 inches. In this case, the height of the sides 27 a, 27 b may each be approximately 1½ inches and the width 27 c′ of the top channel 27 may be approximately 14 inches. Also, in this type of embodiment, each of the planks comprising the horizontal plank 51 (or any of the horizontal planks 51, 52, 53), may each be comprised of a different material or combination of materials and have different dimensions (i.e., different widths and thicknesses) depending upon the taste of the user of the modular shelving 10. Further, in some embodiments, the horizontal planks 51, 52, 53 may each be comprised of a different material. For example, in the embodiment of the modular shelving 10 illustrated in FIG. 1, the top horizontal plank 51 may be comprised of metal, the lower horizontal plank 52 may be comprised of wood, and the third horizontal plank 53 may be comprised of a rigid polymer, such as polyvinyl chloride. Although the modules 20, 30, 40 illustrated in FIG. 1 each have a top channel 27, 37, 47, respectively, it is to be noted that in other embodiments one or more of the modules 20, 30, 40 may have a different shape of top channel 27, 37, 47, respectively, or may not have a top channel 27, 37, 47, respectively, at all, depending upon the aesthetic taste of the user of, and the desired use of, the modular shelving 10.
In the embodiment of the modular shelving 10 illustrated in FIG. 1, and referring again to the module 20 also illustrated in FIG. 2 through FIG. 4 as an example, the module 20 has two interior channels 28, 29, which are positioned within the body of the module 20. In this embodiment, each interior channel 28, 29 is approximately rectangular in shape with two side surfaces 28 a, 28 b and 29 a, 29 b, respectively, a lower surface 28 c, 29 c, respectively, and a slightly concave upper surface 28 d, 29 d, respectively. Preferably, the two side surfaces 28 a, 28 b and 29 a, 29 b are perpendicular to lower surfaces 28 c, 29 c, respectively. The interior channels 28, 29 are of a size and orientation adapted to receive and support a first lower horizontal plank 52 and a second lower horizontal plank 53, respectively, in an orientation approximately horizontal to the support surface 11. In other embodiments, the module 20 may have either fewer interior channels 28, 29 or more interior channels 28, 29. For example, any module 20 may have only one interior channel or may have three or more interior channels. The preferred number of interior channels 28, 29 to be utilized in any module 20 is dependent upon a number of parameters, such as the desired number of horizontal planks 51, 52, 53 to be used with the modular shelving 10, the load to be placed on the horizontal planks 51, 52, 53, the unique structural characteristics of the module 20, and the individual taste of the user of the modular shelving 10. More preferred, the number of interior channels 28, 29 for the module 20 having the preferred size described below is three. In other embodiments where the module 20 may be larger, the more preferred number of interior channels 28, 29 is five or fewer. In the embodiment of the modular shelving 10 illustrated in FIG. 1, the top channel 27 and the two interior channels 28, 29 are all oriented in the same direction, so that the horizontal planks 51, 52, 53 all extend from the module 20 in approximately the same direction. It is to be noted, however, that in other embodiments of the modular shelving 10, the interior channels 28, 29 may be oriented in different directions from one another or may be oriented in different directions from the top channel 27, or any combination thereof. For example, in the embodiment of the module 120 illustrated in FIG. 6, the top channel 127 and a lower interior channel 129 may face the same direction, while an upper interior channel 128 faces in a direction approximately perpendicular to the top channel 127 and the lower interior channel 129. This would allow the module 120 to be used as the corner support in a modular shelving 110 unit designed for use in a corner of a room, with two shelves 151, 153 extending from the module 20 along one wall and a third shelf 152 extending from the module 120 along the other wall.
Referring again to the embodiment illustrated in FIG. 1, and to the embodiment of the upper interior channel 28 of the module 20 illustrated in FIG. 2 through FIG. 4 as an example, the interior channel 28 is approximately rectangular in shape with a slightly concave upper surface 28 d. In this embodiment, the “rectangular portion” of the interior channel 28, which is generally defined as the cross-sectional area of the interior channel 28 bounded by the sides 28 a, 28 b and the lower surface 28 c, is generally of a size and orientation adapted to receive and support the lower horizontal plank 52 in an orientation approximately horizontal to the support surface 11. In other embodiments, the upper surface 28 d may be approximately parallel to the lower surface 28 c (rather than having a slightly concave shape), in which case the “rectangular portion” of the interior channel 28 is generally defined as the cross-sectional area of the interior channel 28 bounded by the sides 28 a, 28 b, the lower surface 28 c, and the upper surface 28 d. Preferably, as illustrated in FIG. 1, the sides 28 a, 28 b of interior channel 28 are approximately the same height as the thickness of the lower horizontal plank 52, so that the cross-sectional area of the lower horizontal plank 52 is approximately the same as and fills the rectangular portion of the interior channel 28 of the module 20. This allows the lower horizontal plank 52 to be held in place (or gripped) by the module 20 in a manner that does not require tools or fasteners. In addition, the lower horizontal plank 52 may be easily removed from the interior channel 28 when it is desired to disassemble the modular shelving 10. Although this is the preferred effect in this embodiment, it is to be noted that in other embodiments the sides 28 a, 28 b of the interior channel 28 may both be higher than the thickness of the lower horizontal plank 52, so that the cross-sectional area of the lower horizontal plank 52 is less than the rectangular portion of the interior channel 28 of the module 20. As described in more detail below with respect to the modular shelving 10 illustrated in FIG. 1 through FIG. 5, this allows a horizontal plank 52 with a degree of warping to be accommodated by the interior channel 28. The lower surface 28 c of the interior channel 28 is preferably approximately parallel to the support surface 11, so that the lower horizontal plank 52 rests adjacent to the entire lower surface 28 c of the interior channel 28 along the thickness 23′ of the module 20. In addition, this also allows the module 20 to support the lower horizontal plank 52 in a manner so that the lower horizontal plank 52 is approximately parallel to the support surface 11. Preferably, as illustrated in FIG. 1, the width 28 c′ of the lower surface 28 c of the interior channel 28 is approximately the same as the width 52 b of the lower horizontal plank 52, so that the sides 52 c, 52 d of the lower horizontal plank 52 fit tightly against the sides 28 a, 28 b, respectively, of the interior channel 28. It is not necessary, however, that this be the case in all embodiments, as long as the lower horizontal plank 52 is held in place by the remaining interior surfaces 28 a, 28 b, 28 c, 28 d of the interior channel 28 while the lower horizontal plank 52 is positioned within the interior channel 28. In the preferred embodiment, as illustrated in FIG. 1 through FIG. 4, the interior channel 28 is constructed in a manner that allows the lower horizontal plank 52 to have a slight warp and still be able to fit into the interior channel 28. For example, as illustrated in FIG. 5, which is a detailed, enlarged view of the left side area of the interior channel 28, as viewed from above the side surface 25, the upper surface 28 d may have a slightly concave shape. In these embodiments, the portion 28 d′ of the upper surface 28 d adjacent to side 28 a (and also the portion of the upper surface 28 d adjacent to side 28 b, but not illustrated in detail) is approximately parallel to the lower surface 28 c. At a predetermined distance away from the side 28 a, the upper surface 28 d is slightly indented in a direction away from the lower surface 28 c, as illustrated in FIG. 5. Moving along the indented portion of the upper surface 28 d toward the other side 28 b, the upper surface 28 d preferably becomes approximately parallel to the lower surface 28 c at a point prior to the midway point (the “midpoint”) between side 28 a and side surface 28 b, and remains approximately parallel to the lower surface 28 c until reaching such midpoint. Preferably, the portion of the upper surface 28 d between such midpoint and the side 28 b has a shape that is approximately symmetrical with the shape of the upper surface 28 d between the side 28 a and such midpoint. Thus, the slightly concave shape of the upper surface 28 d allows the interior channel 28 to accept a lower horizontal plank 52 that has a slight warping of its surface 52 a instead of a relatively flat surface 52 a, while still allowing the lower horizontal plank 52 to be held firmly in place within the interior channel 28. The preferred width 28 c′ of the interior channel 28, the preferred height of the sides 28 a, 28 b of the interior channel 28, and the preferred height of the interior channel 28 at its midpoint (the perpendicular distance between the lower surface 28 c and the upper surface 28 d at the midpoint) are dependent upon a number of factors, such as the width 52 b and thickness of the lower horizontal plank 52, the degree of any warping of the lower horizontal plank 52, the expected loading on the lower horizontal plank 52, the unique structural characteristics of the module 20, and the individual taste of the user of the modular shelving 10. For example, in the illustrated embodiment, the lower horizontal plank 52 may be a standard wooden 1×12 plank (¾″×11½″), in which case the height of the sides 28 a, 28 b may each be approximately ¾ inches, the height at the midpoint may be ⅞ inches, and the width 28 c′ of the interior channel 28 may be approximately 11⅝ inches. It should be noted that the lower horizontal plank 52 (and the lower horizontal plank 53) may have substantially the same structure, features and characteristics, or any combination thereof, described above with respect to the top horizontal plank 51. Thus, in order to produce an aesthetically pleasing look to some users of the modular shelving 10, the lower horizontal plank 52 may also be a series of four standard 2×4 (1½″× 3/2″) wooden planks laid side-by-side, producing a lower horizontal plank 52 having an overall thickness of approximately 1½ inches and an overall width of approximately 14 inches. In this case, the height of the sides 28 a, 28 b may each be approximately 1½ inches, the height at the midpoint may be 1 11/16 inches, and the width 27 c′ of the interior channel 28 may be approximately 14 inches. Although the modules 20, 30, 40 illustrated in FIG. 1 each have two interior channels 28, 29, 38, 39, 48, 49, respectively, that are approximately rectangular in shape with a slightly concave upper surface, it is to be noted that in other embodiments one or more of the modules 20, 30, 40 may have different shapes of interior channels 28, 29, 38, 39, 48, 49, respectively, or may not have interior channels 28, 29, 38, 39, 48, 49, respectively, at all, depending upon the aesthetic taste of the user of, and the desired use of, the modular shelving 10.
Each of the modules 20, 30, 40 may be constructed of any suitable materials or combinations of such materials. For example, the modules 20, 30, 40 may be constructed of metal, glass, wood, pressboard, rigid, semi-rigid and flexible polymers (such as polyethylene or polypropylene), paper, fabric, cloth, fiberglass and carbon composites, resins, minerals, other artificial and naturally occurring materials, or combinations of such materials currently known in the art or that may be discovered in the art in the future. Preferably, and referring again to the embodiment of module 20 illustrated in FIG. 1 through FIG. 4 as an example, each module 20 is constructed in a manner so that the bottom surface 21, the top surface 22, the sides 27 a, 27 b and the bottom surface 27 c of the top channel 27, the two end surfaces 23, 24, and the two side surfaces 25, 26 are each constructed of a rigid, semi-rigid or flexible material, which creates an exterior shell encompassing the outside surfaces of the module 20. For modules having shapes other than the module 20 illustrated in FIG. 1 through FIG. 4, the exterior shell generally conforms to the shape of the exterior surfaces of the modules. In some embodiments, all or some of such exterior surfaces of the module 20 comprising the exterior shell may be constructed of a rigid material, such as wood, metal, glass, fiberglass and carbon composites, a rigid polymer material, or combinations of such materials. In these embodiments, the exterior shell of the module 20 may be the primary structural component in supporting the horizontal planks 51, 52, 53, or the exterior shell of the module 20 may contribute, along with an internal support means (such as a rigid foam or other structural members or materials, as described in more detail below), to the structural support of the horizontal planks 51, 52, 53. In such embodiments, the preferred material of construction of the exterior shell of the module 20 generally depends upon a number of parameters, such as the widths and thicknesses of the horizontal planks 51, 52, 53, the expected loading on the horizontal planks 51, 52, 53, the desired thickness of the exterior shell, the unique shape and structural characteristics of the module 20, the proportions of structural support to be provided by the exterior shell and any internal support means of the module 20, and the individual taste of the user of the modular shelving 10. In such embodiments, the preferred thickness of the exterior shell of the module 20 generally depends upon a number of parameters, such as the widths and thicknesses of the horizontal planks 51, 52, 53, the expected loading on the horizontal planks 51, 52, 53, the materials comprising the exterior shell, the unique shape and structural characteristics of the module 20, the proportions of structural support to be provided by the exterior shell and any internal support means of the module 20, and the individual taste of the user of the modular shelving 10. More preferably, for a module 20 having an exterior shell constructed of polyethylene that is intended to provide primary support for the horizontal planks 51, 52, 53 without significant support provided by internal support means, the exterior shell has a thickness in the range from ⅛ inches to 3/16 inches. In some embodiments, the sides 28 a, 28 b, 29 a, 29 b, the lower surfaces 28 c, 29 c, and the upper surfaces 28 d, 29 d of the two interior channels 28, 29 may also be comprised of similar types of flexible, semi-rigid, or rigid materials or combinations of such materials, which also constitute a part of the exterior shell encompassing the interior channels 28, 29 (except for the open ends of the interior channels 28, 29), so that the volume within the module 20 is completely enclosed and may be (but need not necessarily be) made fluid-tight. The interior volume of the module 20 in these embodiments is therefore hollow and may be filled with air or another gas at ambient pressure or a greater or lesser pressure. In other embodiments, the interior volume of the module 20 may have internal support means positioned therein. For example, the interior volume of the exterior shell of the module 20 may be filled with a rigid or semi-rigid foam material, such as polyurethane, polystyrene, or combinations of such materials. In these embodiments, the rigid or semi-rigid foam material may also provide additional structural strength, allowing the module 20 to support a greater load, where the exterior surfaces of the rigid or semi-rigid foam material are rigidly attached to the interior surfaces of the exterior shell of the module 20 causing loads placed on the rigid or semi-rigid foam material to be distributed to and dissipated within the exterior shell of the module 20. It is to be noted that the rigid or semi-rigid foam material may also be used in embodiments of the module 20 where the surfaces of the two interior channels 28, 29 (and possibly the top channel 27) are not constructed of a material described above in a manner that creates a part of the exterior shell encompassing such surfaces. In these embodiments, the rigid or semi-rigid foam material may be exposed to the environment at such surfaces, without a shell constructed of a different material to separate the rigid or semi-rigid foam from the environment at such surfaces. Also in these embodiments, the exterior shell of the module 20 may be constructed of semi-rigid or flexible materials, such as semi-rigid and flexible polymers (such as polyethylene or polypropylene), paper, fabric, cloth, other semi-rigid or flexible artificial and naturally occurring materials, or combinations of such materials, because the primary structural strength of the module 20 may reside in the rigid or semi-rigid foam material. In these embodiments, the encompassing semi-rigid or flexible exterior shell of the module 20 acts primarily to maintain the shape of the module 20, as well as to protect the rigid or semi-rigid foam material and hold it securely in place. In still other embodiments, the module 20 may contain other internal support means, which may comprise any number of suitable structural members and combinations of such members necessary or desirable to provide additional structural support for the modular shelving 10. For example, the module 20 may also comprise one or more internal rigid support members extending vertically or diagonally between the bottom surface 21 and the lower surface 29 c of the interior channel 29, between the upper surface 29 d of the interior channel 29 and the lower surface 28 c of the interior channel 28, or between the upper surface 28 d of the interior channel 28 and the lower surface 27 c of the top channel 27 or the top surface 22, or between any combination of any such surfaces. Examples of such additional internal support are represented by the internal vertical support members 60, 61 illustrated in FIG. 2, which extend between the upper surface 29 d of the lower interior channel 29 and the lower surface 27 c of the top channel 27. The internal support means (as represented by vertical support members 60, 61) may be constructed of any rigid material, such as wood, metal or rigid plastic, and may take the form of any suitable structure or geometry, such as trusses, cross-bracing, H-shaped supports, honeycomb-shaped supports, corrugated-shaped supports, or combinations of such structures. Further, other materials and combinations of materials, such as cardboard or “bubble wrap,” may be positioned within the interior volume of the module 20 to provide additional structural support.
More preferably, the module 20 may be of almost any shape described above in connection with FIG. 1 through FIG. 9, have an exterior shell comprised of molded polyethylene that has a thickness in the range from 1/16 inches to 3/16 inches, and an interior volume filled with polyurethane foam. This type of construction generally produces a module 20 having a relatively pliable exterior shell, so that if a person falls against it, the exterior shell may deform in a manner that absorbs some of the energy of the impact and dissipates the pressure loading over a greater surface area. The person is therefore less likely to suffer injury as a result of a fall against this type of module 20, as opposed to a module 20 constructed of a more rigid material. In addition, this type of exterior shell may also be produced with any number of different exterior surfaces, such as a shot peen texture or wood, fabric or marble finish. Further, modules 20, 30, 40 having this composition generally possess significant structural strength. They are also generally lightweight and easily moved, so that handling and shipping costs may be reduced. A module 20 of this composition may also be constructed in a relatively inexpensive manner, such as by the preferred means of rotomolding, with foam injection, which are techniques well known in the relevant art.
The preferred number of modules 20, 30, 40 to be used in any unit of modular shelving 10 is also dependent upon the unique structural characteristics of the modules 20, 30, 40 themselves. For example, fewer modules 20, 30, 40 may be required where the modules 20, 30, 40 are capable of supporting more weight and providing greater stability. This may be the case where the modules 20, 30, 40 have a greater exterior shell thickness, larger size, internal support means, or any combination of the same. In contrast, where the modules 20, 30, 40 are smaller, have a thinner exterior shell, utilize less internal support means, or have a smaller thickness 23′, more of them may be required to provide the necessary support and stability. Preferably, the span of any horizontal plank 51, 52, 53 between any two modules 20, 30, 40 is in the range between three feet and four feet. More preferred, the span of any horizontal plank 51, 52, 53 between any two modules 20, 30, 40 is less than four feet. Referring to the module 20 illustrated in FIG. 1 through FIG. 4 as an example, the thickness 23′ of the module 20 must generally be great enough to provide adequate structural strength to prevent the modular shelving 10 from collapsing in the direction along the longitudinal axis of the horizontal planks 51, 52, 53. If the thickness 23′ is too small, lateral force applied to the module 20 along the longitudinal axis of heavily loaded horizontal planks 51, 52, 53 could overcome the ability of the module 20 to resist such movement, causing the top of the module 20 to move in the direction of the applied force and collapsing the modular shelving 10 in that direction. For the embodiment of the module 20 illustrated in FIG. 1 through FIG. 4, wherein the module 20 is constructed of molded polyethylene with a polyurethane foam interior having a thickness in the range of 1/16 inches to 3/16 inches, the preferred thickness 23′ of the module 20 is preferably in the range from four inches to five inches. Generally, the more preferred thickness 23′ is dependent upon a number of parameters, such as the length and width of the horizontal planks 51, 52, 53, the position of the module 20 in the modular shelving 10 (e.g., at the end of a horizontal plank 51, 52, 53, as is the case with modules 20 and 40 in FIG. 1, as opposed to an interior position, as is the case with module 30 in FIG. 1), the expected loading on the horizontal planks 51, 52, 53, the unique shape and structure of the module 20, and the individual taste of the user of the modular shelving 10. In addition, the side surfaces 25, 26 of the module 20 must generally be of a size great enough to accommodate the width 27 c′ of the top channel 27 and the width 28 c′ of any interior channels 28, 29. In the embodiment of the modular shelving 10 illustrated in FIG. 1, for modules 20, 30, 40 constructed of molded polyethylene that are filled with polyurethane foam, the most preferred thickness 23′ is approximately 4½ inches, and the dimensions of the two side surfaces are approximately 24 inches high by approximately 14½ inches wide. Further, in the preferred embodiments of the modules 20, 30, 40, the outside edges of the exterior shell of the modules 20, 30, 40 are each rounded. For example, and referring again to module 20 as an example, the corners bounded by the end surfaces 23, 24 and the side surfaces 25, 26 preferably have rounded edges having a radius of curvature of 5/32 inches. In addition, the corners bounded by the bottom surface 21 preferably have rounded edges having a radius of curvature of 3/16 inches, while the corners bounded by the top surface 22 and the end surfaces 23, 24 preferably have rounded edges having a radius of curvature of ¼ inches. The rounded edges permit the modules 20, 30, 40 to be moved over the support surface 11 more easily and in some embodiments, where preferred by the user, may also serve to eliminate sharp corners that may cause injury if a person should fall against them.
It is to be noted that the thickness 23′ of the module 20 may also be decreased in certain circumstances without a decrease in stability of the modular shelving 10. Referring to the module 220 of FIG. 7A and FIG. 7B as an example, the thickness of the module 220 may be decreased without a corresponding decrease in the stability of the modular shelving 210 where support brackets 227 e, 228 e, 229 e are used in conjunction with interior channels 227, 228, 229 of the module 220. The support brackets 227 e, 228 e, 229 e provide additional support for the horizontal planks (not illustrated), as well as additional stability along the longitudinal axis of the horizontal planks of the modular shelving (not illustrated) incorporating modules 220 having support brackets 227 e, 228 e, 229 e, so that the modular shelving does not collapse in the direction of that axis in the manner described above. Referring to support bracket 227 e as an example, as illustrated in perspective in FIG. 7A and FIG. 7C, and in cross-section in FIG. 7B, the support bracket 227 e is comprised of a support portion 227 e′ and an adapter portion 227 e″ that is positioned beneath the support portion 227 e′. The adapter portion 227 e″ is preferably shaped as illustrated in FIG. 7A through FIG. 7C, and is of a size and shape adapted to fit into the channel 227 so that the support bracket 227 e fits snugly within the channel 227, and against the lower surface of the channel 227, in the manner illustrated. This allows the support bracket 227 e to be held in place in the channel 227 in a manner that does not require tools or fasteners. In addition, the support bracket 227 e may be easily removed from the interior channel 227 when desired. The support portion 227 e′ protrudes from the side surfaces 225, 226 a predetermined distance along the longitudinal axis of the horizontal planks (not illustrated). The support portion 227 e′ is held in place in the module 220 by means of the adapter portion 227 e″, which may be any suitable structure in various embodiments. Although the adapter portion 227 e″ may extend along the entire width of the support bracket 227 e in some embodiments, it need not extend the entire width in other embodiments of the module 227. In addition, the support bracket 227 e may extend along the entire width of the channel 227, as illustrated in FIG. 7A, or it may only extend along a portion of the width of the channel 227. Generally, the preferred size of any support bracket 227 e is dependent upon a number of parameters, such as the length and width of the horizontal planks, the position of the module 220 in the modular shelving (e.g., at the end of a horizontal plank, as is the case with modules 20 and 40 in FIG. 1, as opposed to an interior position, as is the case with module 30 in FIG. 1), the expected loading on the horizontal planks, the unique shape and structure of the module 220, and the individual taste of the user of the modular shelving. More preferred, the support brackets 227 e, 228 e, 228 e extend along the entire width of the interior channels 227, 228, 228 and extend along the longitudinal axis of the horizontal planks (not illustrated) a distance in the range of one inch to three inches. It is to be noted that in other embodiments the support brackets 227 e, 228 e, 229 e may have different shapes and be of different sizes. In operation, the support brackets 227 e, 228 e, 229 e are positioned in the channels 227, 228, 229, respectively, and the horizontal planks (not illustrated) are placed on the top surface of the support brackets 227 e, 228 e, 229 e.
The present invention also includes a method for assembling and using the modular shelving 10. This method generally includes the actions described below. First, the user of the modular shelving 10 places the desired number of modules (such as the modules 20, 30, 40 in the embodiment illustrated in FIG. 1) on the support surface 11 in the desired orientation for the modular shelving 10. Second, the user of the modular shelving 10 places the horizontal planks 51, 52, 53 in the desired position in the top channels 27, 37, 47 and the interior channels 28, 29, 38, 39, 48, 49. For example, this may be accomplished by sliding a lower horizontal plank 52 into the upper interior channel 28 of module 20, continuing to slide the lower horizontal plank 52 through module 20 into and through the upper interior channel 38 in module 30, continuing to slide the lower horizontal plank 52 through module 20 and module 30 into and through the upper interior channel 48 in module 40, and halting the sliding when the lower horizontal plank 52 is in the desired position in the modular shelving 10.
It is to be noted that in some embodiments, the modules 20, 30, 40 may be stacked upon one another. For example, in the embodiment of the modular shelving 10 illustrated in FIG. 1, another structure substantially the same as the illustrated modular shelving 10 may be positioned upon the illustrated modular shelving 10. In this case, each of the additional modules (not illustrated) is placed on top of one of the illustrated modules 20, 30, 40, so that the bottom surface of the additional module is placed adjacent to the top surface 22, 32, 42 of the appropriate illustrated module 20, 30, 40. Also in this case, the additional modules may be permanently attached to the illustrated modules 20, 30, 40, or the additional modules may be removably attached to the illustrated modules 20, 30, 40. The means of attachment may be any suitable means, such as glues, adhesives, adhesive tape, nails, nuts and bolts, screws, brackets, pins, dowels, clips, clasps, hook and loop fastening systems (VELCRO), or other means or combinations of such means. It is also to be noted that the additional modules need not be of the same size or shape as the module 20, 30, 40 upon which it is placed.

Claims

1. A module for use in modular shelving, wherein:

(a) the module is comprised of an exterior shell having an ornamental or functional shape, wherein the exterior shell is further comprised of a bottom surface and at least a portion of the bottom surface rests on a support surface;

(b) the exterior shell is comprised of a rigid material;

(c) the module has at least one channel positioned therein, wherein the at least one channel is of a size and orientation adapted to receive and hold at least one horizontal plank; and

(d) the at least one horizontal plank is supported by the module in an orientation approximately horizontal to the support surface while the at least one horizontal plank is positioned within the at least one channel.

2. The module of claim 1, wherein the at least one channel is an interior channel that is approximately rectangular in shape.

3. The module of claim 1, wherein the at least one channel is an interior channel that is approximately rectangular in shape with a slightly concave upper surface.

4. The module of claim 2, wherein:

(a) the module is further comprised of a top surface approximately opposite the bottom surface; and

(b) the module has a top channel positioned in the top surface thereof, wherein:

(i) the top channel is approximately rectangular in shape and is of a size and orientation adapted to receive and hold a top horizontal plank; and

(ii) the top horizontal plank is supported by the module in an orientation approximately horizontal to the support surface while the top horizontal plank is positioned within the top channel.

5. The module of claim 4, wherein the top horizontal plank and the at least one horizontal plank each extend from the module in a different direction while the top horizontal plank is positioned in the top channel and the at least one horizontal plank is positioned in the at least one interior channel.

6. The module of claim 1, wherein the rigid material comprising the exterior shell is comprised of a rigid polymer material and the exterior shell has a thickness in the range from ⅛ inches to 3/16 inches.

7. The module of claim 1, further comprising internal support means, wherein the internal support means provides additional support for the at least one horizontal plank.

8. The module of claim 7, wherein the internal support means are comprised of at least one structural member extending:

(a) from at least one point on an interior surface of the exterior shell to at least one other point on the interior surface of the exterior shell of the module;

(b) from at least one point on the interior surface of the exterior shell to at least one point on a surface of the at least one channel of the module; or

(c) from at least one point on the surface of the at least one channel of the module to at least one other point on the surface of an at least one channel of the module.

9. The module of claim 7, wherein the module has an interior volume bounded by the exterior shell and the internal support means is comprised of a rigid foam material positioned within the interior volume of the module.

10. The module of claim 1, further comprising at least one support bracket, wherein the at least one support bracket is positioned in the at least one channel, the at least one support bracket extends outward from the exterior shell along the longitudinal axis of the at least one horizontal plank, and the at least one support bracket provides additional support for the at least one horizontal plank.

11. A module for use in modular shelving, the module comprising:

(a) an exterior shell comprised of a flexible or semi-rigid material and having an ornamental or functional shape, wherein the exterior shell is further comprised of a bottom surface and at least a portion of the bottom surface rests on a support surface; and

(b) a rigid foam material positioned within the interior volume bounded by the exterior shell, wherein;

(i) the module has at least one channel positioned therein, wherein the at least one channel is of a size and orientation adapted to receive and hold at least one horizontal plank in an orientation approximately horizontal to the support surface; and

(ii) the at least one horizontal plank is supported by the module in an orientation approximately horizontal to the support surface while the at least one horizontal plank is positioned within the at least one channel.

12. The module of claim 11, wherein the at least one channel is an interior channel that is approximately rectangular in shape.

13. The module of claim 11, wherein the at least one channel is an interior channel that is approximately rectangular in shape with a slightly concave upper surface.

14. The module of claim 11, wherein:

15. The module of claim 14, wherein the top horizontal plank and the at least one horizontal plank each extend from the module in a different direction while the top horizontal plank is positioned in the top channel and the at least one horizontal plank is positioned in the at least one interior channel.

16. The module of claim 11, wherein the flexible or semi-rigid material comprising the exterior shell is comprised of a flexible or semi-rigid material polymer material and the exterior shell has a thickness in the range from 1/16 inches to 3/16 inches.

17. The module of claim 16, wherein the polymer material is molded polyethylene.

18. The module of claim 11, further comprising internal support means, wherein the internal support means provides additional support for the at least one horizontal plank.

19. The module of claim 11, further comprising at least one support bracket, wherein the at least one support bracket is positioned within the at least one channel, the at least one support bracket extends outward from the exterior shell along the longitudinal axis of the at least one horizontal plank, and the at least one support bracket provides additional support for the at least one horizontal plank.

20. A modular shelving system comprised of:

(a) at least one first module, comprising:

(i) a flexible or semi-rigid exterior shell having an ornamental or functional shape and a bottom surface, wherein at least a portion of the bottom surface rests on a support surface; and

(ii) a rigid foam material positioned within the interior volume bounded by the exterior shell;

(b) at least one second module comprised of an exterior shell having an ornamental or functional shape and a bottom surface, wherein at least a portion of the bottom surface rests on a support surface; and

(c) at least one horizontal plank, wherein:

(i) the at least one first module and the at least one second module each have at least one channel having a rectangular bottom portion positioned therein, wherein the at least one channel is of a size and orientation adapted to receive and hold a portion of the at least one horizontal plank; and

(ii) the at least one horizontal plank is supported by the at least one first module and the at least one second module in an orientation approximately horizontal to the support surface while the at least one horizontal plank is positioned within the at least one channel of the at least one first module and the at least one channel of the at least one second module.

21. The modular shelving system of claim 20, wherein the exterior shell of the at least one second module is comprised of a rigid material.

22. The modular shelving system of claim 20, wherein the at least one second module further comprises internal support means to provide additional support for the at least one horizontal plank.

23. The modular shelving system of claim 20, wherein the at least one channel in the at least one first module is an interior channel.

24. The modular shelving system of claim 23, wherein:

(a) the at least one first module is further comprised of a top surface approximately opposite the bottom surface; and

(b) the at least one first module has a top channel positioned in the top surface thereof, wherein:

(i) the top channel is approximately rectangular in shape and is of a size and orientation adapted to receive and hold a top horizontal plank;

(ii) a portion of the top horizontal plank is positioned within one of the at least one channels of the at least one second module; and

(iii) the top horizontal plank is supported by the at least one first module and the at least one second module in an orientation approximately horizontal to the support surface while the top horizontal plank is positioned within the top channel of the at least one first module and the at least one channel of the at least one second module.

25. The modular shelving system of claim 24, wherein the top horizontal plank and the at least one horizontal plank each extend from the at least one first module in a different direction while the top horizontal plank is positioned in the top channel of the at least one first module and the at least one horizontal plank is positioned in the at least one interior channel of the at least one first module.

26. The modular shelving system of claim 20, wherein the material comprising the exterior shell of the at least one first module is comprised of a flexible or semi-rigid polymer material and the exterior shell of the at least one first module has a thickness in the range from 1/16 inches to 3/16 inches.

27. The modular shelving system of claim 20, wherein the at least one first module further comprises at least one support bracket, wherein the at least one support bracket is positioned in the at least one channel of the at least one first module, the at least one support bracket extends outward from the exterior shell of the at least one first module along the longitudinal axis of the at least one horizontal plank, and the at least one support bracket provides additional support for the at least one horizontal plank.

28. The modular shelving system of claim 20, further comprising at least one third module, wherein:

(b) the at least one third module is comprised of an exterior shell having an ornamental or functional shape and a bottom surface, wherein at least a portion of the bottom surface of the at least one third module rests on a portion of the top surface of the at least one first module;

(c) the at least one third module has at least one channel having a rectangular bottom portion positioned therein, wherein the at least one channel is of a size and orientation adapted to receive and hold a portion of at least one second level horizontal plank; and

(d) the at least one second level horizontal plank is supported by the at least one third module in an orientation approximately horizontal to the support surface while the at least one second level horizontal plank is positioned within the at least one channel of the at least one third module.

29. A modular shelving system comprised of:

(a) at least one first module comprising a rigid exterior shell having an ornamental or functional shape and a bottom surface, wherein at least a portion of the bottom surface rests on a support surface;

(c) at least one horizontal plank, wherein:

30. The modular shelving system of claim 29, wherein the exterior shell of the at least one second module is comprised of a flexible or semi-flexible material and a rigid foam material is positioned within the interior volume bounded by the exterior shell of the at least one second module.

31. The modular shelving system of claim 29, wherein the at least one first module further comprises internal support means to provides additional support for the at least one horizontal plank.

32. The modular shelving system of claim 29, wherein the at least one channel in the at least one first module is an interior channel.

33. The modular shelving system of claim 32, wherein:

(i) the top channel is approximately rectangular in shape and is of a size and orientation adapted to receive a top horizontal plank;

34. The modular shelving system of claim 33, wherein the top horizontal plank and the at least one horizontal plank each extend from the at least one first module in a different direction while the top horizontal plank is positioned in the top channel of the at least one first module and the at least one horizontal plank is positioned in the at least one interior channel of the at least one first module.

35. The modular shelving system of claim 29, wherein the rigid material comprising the exterior shell of the at least one first module is comprised of a rigid polymer material and the exterior shell of the at least one first module has a thickness in the range from 1/16 inches to 3/16 inches.

36. The modular shelving system of claim 29, wherein the at least one first module further comprises at least one support bracket, wherein the at least one support bracket is positioned in the at least one channel of the at least one first module, the at least one support bracket extends outward from the exterior shell of the at least one first module along the longitudinal axis of the at least one horizontal plank, and the at least one support bracket provides additional support for the at least one horizontal plank.

37. The modular shelving system of claim 29, further comprising at least one third module, wherein: