US20170065078A1

US20170065078A1 - Shelving connector

Info

Publication number: US20170065078A1
Application number: US15/253,366
Authority: US
Inventors: Azad Sabounjian; Sam C. Sabounjian
Original assignee: Pro Mart Industries Inc
Current assignee: Pro Mart Industries Inc
Priority date: 2015-09-04
Filing date: 2016-08-31
Publication date: 2017-03-09
Also published as: WO2017040835A1

Abstract

A sleeve for a shelving unit has two halves joined together to form two support tabs extending outward from opposing sides of the sleeve as the sleeve clamps around a post having grooves into which a rib on the sleeve fits to hold the parts relative to the post. The support tabs have a retaining flange offset from the sleeve. A first collar part fastened to a shelf fits over half the sleeve and fits into that offset so that a slot in the first collar part fits over one of the support tabs to clamp them to the post and support the first collar part and shelf. The retaining flange keeps the collar part from moving off the support tab. A second collar part with a second slot may fit over the other support tabs to support a second shelf or to further clamp the sleeve to the post. Interlocking means on the collar parts prevent lateral separation.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The application claims the benefit under 35 U.S.C. §119(e) to Provisional Patent Application No. 62/214,804 filed Sep. 4, 2015, the entire contents of which are incorporated herein by reference.

BACKGROUND

The present invention relates generally to a support structure that can be used to support shelving or other elements for carrying or supporting any desired item. More particularly, the present invention relates to a support assembly for use in, for example, a knock-down shelving system to adjustably support shelves.
Current knock-down shelving systems include a plurality of support posts for supporting one or more shelves at corner support assemblies thereof. These shelving systems have a sleeve or wedge member and an encircling collar both adapted to be secured to a generally cylindrical support post having a circular cross-section. The sleeve has an inner surface that is configured to embrace the support post and has an outer surface that is wedge shaped usually taking the form of a frusto-conical shape with a narrower diameter at the top and a larger diameter at the bottom. The collar has an outer surface that is secured to a shelf. The collar has an internal wedge surface formed to mate with the frusto-conical wedge surface of the sleeve but either inclined in the opposing direction or having a smaller upper opening which does not allow passage of the sleeve on the post. Thus, when the sleeve embraces the post and the collar embraces the sleeve, axial loading of the collar in one direction causes the collar's inward facing wedge surface to mate with the outward facing wedge surface on the sleeve, thereby urging the sleeve toward the post. Since the collar is restrained from radial expansion and has a fixed diameter, and since relative movement of the inclined surfaces of the sleeve and the collar want to increase in diameter as they move relative to one another in axially opposing directions, the non-expandable outer collar forces the sleeve inward and clamps the sleeve against the post and wedges the collar and sleeve into place on the post.
Such shelving systems are disclosed in U.S. Pat. Nos. 3,424,111 and 3,523,508, which use a plurality of cylindrical support posts each formed with a series of equally spaced, annular grooves on its outer surface. A basic shelving system includes four such posts to support one or more formed-wire shelves, with each shelf having a frusto-conically-shaped collar at each corner for receiving a support post. A two-piece interlocking sleeve fits around the support post. The sleeve has a circumferential rib on its interior surface for engaging one of the grooves on the support post and has a frusto-conically-shaped outer surface, which is widest at the bottom, designed to complement the shape of the shelf collars. The support posts fitted with sleeves are received in the collars of each shelf to assemble the shelving system. When assembled, the weight of the shelf and any items placed on the shelf pushes downward on the collar and sleeve, creating a radially-inwardly directed wedging force between the collars and sleeves, which brings the sleeves into tight contact with the posts. Similar wedging concepts are used in U.S. Pat. Nos. 4,811,670; 4,946,350; 5,271,337; 5,279,231 and 6,113,042. Some of these devices use over-center cams to ensure the collars are locked in place.
Further, the above described collars have a fixed diameter and thus pass along the length of the post until they reach the sleeve with which they wedge against the post. That requires assembling the shelving from the bottom up or the top down since the collars cannot be positioned between two previously installed shelves. Further, a shelf cannot be inserted between pre-installed shelves since the collars cannot slide over previously installed sleeves or collars. Because the collars in these prior art connectors were tubular they had to be slid axially over one end of the post in order to mate with the sleeve and wedge the parts in place. To address this difficulty collars which encircles less than a full 360 degrees were developed, with some collars having open vertical slots like U.S. Pat. Nos. 6,302,284 and 6,257,426, and other collars mating with sleeves or other parts along generally vertical axes, as described in U.S. Pat. Nos. 6,068,143 and 4,656,952. But the open slotted collars provide a weak connection because sufficient weight on the shelf and collar will spread the unconnected parts of the collar apart in the circumferential direction, releasing the support. The collars mating with shaped sleeves required more expensive and stronger sleeves. The collars using vertical joints require precise alignment of the vertical joints making them difficult to align and assemble.
Still other connectors placed brackets on the outer, metal collars with the shelving rods engaging the brackets, as shown in U.S. Pat. Nos. 6,015,052 and 6,253,687. These collars required assembling the shelving from the bottom up since the collars cannot be positioned between two previously installed shelves. Further, a shelf cannot be inserted between pre-installed shelves since the collars cannot slide over previously installed sleeves or collars. Because the collars in these prior art connectors were tubular they had to be slid axially over one end of the post in order to mate with the sleeve and wedge the parts in place. There is thus a need for a connector that can allow shelves to be inserted between existing shelves.
Despite the long use of these above-described shelving systems, a need exists for an improved connector and shelving system, especially one easier to assemble and more flexible in its assembly. There is thus a need for an improved shelving connector that may be installed without having to slide the connector along the entire length of the post to the desired shelving position and that may be easily installed.
Further, during shipment or movement of disassembled shelving systems, parts may become lost. Likewise, confusion may arise in combining the correct parts for use. There is thus a need for a way to connect together parts that will be used together when the shelf assembly is being shipped, assembled or disassembled.

BRIEF SUMMARY

A sleeve for a shelving unit has two halves joined together to form two support tabs extending outward from opposing sides of the sleeve as the sleeve clamps around a post having grooves into which a rib on the sleeve fits to hold the parts relative to the post. The support tabs have a retaining flange offset from the sleeve. A first collar part fastened to a shelf fits over half the sleeve and fits into that offset so that a slot in the first collar part fits over one of the support tabs to clamp them to the post and support the first collar part and shelf. The retaining flange keeps the collar part from moving off the support tab. A second collar part with a second slot may fit over the other support tabs to support a second shelf or to further clamp the sleeve to the post. The support tabs may be hinged together by a recessed hinge that does not extend beyond the surface of the hinged parts and that does not interfere with the mating of the collar to the sleeve.
A compression lock is provided on a connector for a shelving post having a longitudinal axis. An inner sleeve has two interlocking parts, each of which is tapered to form a frusto-conical shaped sleeve when assembled. At least one rib extends inward from each part to fit into one of several corresponding grooves spaced at intervals along the length of the post. The sleeves each have at least one outward extending tab from which extends an axially aligned retaining flange such that the tabs offset their retaining flanges from the outward facing surface of the sleeve. There are preferably two tabs and retaining flanges on opposing sides, generally vertical sides of each sleeve so the tabs and retaining flanges of each sleeve abut and form two outward extending tabs and two retaining flanges on opposing sides of the sleeve. A tapered collar part connected to a corner of a shelf fits over at least part of the sleeve with the taper wedging the sleeve toward the post. The collar part has a slot opening onto the bottom periphery of the collar part with a closed interior end. The slot is sized and located to fit over one pair of the abutting tabs and the collar part containing that slot fits between the retaining flanges and the sleeve so the collar part and shelf rest upon the abutting pair of tabs engaged by the collar part, with the retaining flange keeping the collar part from moving away from the sleeve and post. Another shelving unit and collar part may be placed on the another pair of abutting tabs on the collar part, or a retaining flange may be placed on any free pair of abutting tabs in order to lock them together and keep them and the associated parts of the sleeve from splaying. Interlocking means on the collar parts releasably engage to hold the collar parts together and prevent lateral separation.
One interlocking means comprises outwardly extending flanges on one collar part being received in a second collar part, preferably with the male flanges received in a U-shaped groove of the second collar part to engage along a length of the male flange and prevent lateral separation. A second interlocking means comprises slotted tabs on each collar part where the juncture of an outwardly extending tab has a slot extending along a length of the juncture so the slots of one collar part fit over the juncture of a mating collar part to interlock the collar parts with the mating flanges restraining lateral separation. In addition to preventing lateral separation, the mating flanges restrain rotation about two axes when one of the collar parts is fixe to a shelf or through the cooperation of the post.
There is advantageously provided an interlocking collar for use with a sleeve having a frusto-conical outer surface encircling a post having an outer surface with grooves at intervals along a length of the post. A rib on the sleeve mates with one of the grooves. The collar part is configured to wedge the sleeve against the post during use in order to position the sleeve and collar part along a length of the post. The interlocking collar include an annular collar having first and second separable and interlocking collar parts defining a frusto-conical interior passage extending along a longitudinal axis when joined together. The passage is sized to engage the outer surface of the sleeve during use. Each collar part extends about half way around the longitudinal axis and is preferably semi-circular in shape. Each collar part has a top and bottom with the bottom forming a larger diameter of the conical interior passage. A closed ended slot extends through each collar part and extends along the longitudinal axis and opens onto the bottom of each collar part and is configured to engage a pair of the outwardly extending tabs on the sleeve when the tabs abut each other. Interlocking means on each of the first and second collar parts are provided for preventing lateral separation of those interlocked collar parts in a plane transverse to the longitudinal axis during use.
In one variation the interlocking means comprises a male flange having opposing sides and extending outward from each of two opposing sides of the first collar part and extending along a substantial length of each collar part measured along the longitudinal axis. Each male flange may have a thickness T between opposing sides of the flange and extend outward a distance between about 3T and 10T. The corresponding female channel extends outward from each of two opposing sides of the second collar part and extends along a substantial length of the second collar part measured along the longitudinal axis. Each female channel has an open bottom configured to slidably receive one of the male flanges during use, with each female channel extending along opposing sides of a different one of the male flanges during use.
In further variations of this interlocking collar, each male flange has a trapezoidal shape. The first collar part may be connected to a shelf, or the second collar part may be connected to a shelf. The male flange extends generally radially outward.
In a further variation, the interlocking means comprises a first collar part having a top end and bottom end with a distance H1 between the ends measured along the longitudinal axis, the bottom end forming a larger diameter portion of the frusto-conical passage. The first collar part has two first flanges each forming a first juncture with a curved portion of the first collar part as each first flange extends outward from diametrically opposing side of that curved portion of the first collar part. The first flanges may extend a distance from the outside of the curved portion between about 3 and 10 times a thickness of the first flange. The first collar part has two, first closed ended slots extending through a thickness of the first collar along a length of the first juncture and opening onto the top end to define two first flanges each having a free upper end separated from an upper portion of the first collar part and each having a lower end joined to a lower portion of the first collar part along the first juncture during use. The first collar part has a third closed ended slot extending from the bottom end along the longitudinal axis and opening onto the bottom end with the third slot located at about the middle of the curved portion of the first collar part. The third slot is configured to engage a pair of the outwardly extending tables of the sleeve during use and hold them together. This further variation has a second collar part having a top end and bottom end with a distance H2 between the ends measured along the longitudinal axis. The top end forms a smaller diameter portion of the frusto-conical passage. the first collar part has two second flanges each forming a second juncture with a curved portion of the second collar part as each second flange extends outward from diametrically opposing side of that curved portion of the second collar part. The second flanges extends a distance from the outside of the curved portion between about 3 and 10 times a thickness of the second flange/The second collar part has two, second closed ended slots extending through a thickness of the second collar along a length of the second juncture and opening onto the top end to define two second flanges each having a free lower end separated from a lower portion of the second collar part and each having an upper end joined to an upper portion of the second collar part along the second juncture during use. The second collar part has a third closed ended slot extending from the bottom end along the longitudinal axis and opening onto the bottom end of the second collar part. The third slot is located at about the middle of the curved portion of the second collar part and configured to engage two of the outward extending tabs on the sleeve to hold those tabs together. Each first slot is sized to receive a different second juncture and each second slot is sized to receive a different first juncture when the first and second collar parts are engaged by relative movement along the longitudinal axis. Each third slot is sized to engage a different pair of outwardly extending tab on the sleeve during use.
In still further variations, each first flange is generally parallel to a top portion of the second collar part and each second flange is generally parallel to a bottom portion of the first collar part when the first and second collar parts are engaged. Advantageously, wherein H1 and H2 are about the same. The length of the first slots are each about half of H1 and the length of each second slots are about half of H2. Moreover, the first and second collar parts may have a substantially uniform thickness and the first and second flanges may have a side inclined to the longitudinal axis and in a plane with that axis.
There is also advantageously provided a kit for a shelving unit having at least two, generally horizontal shelves connected to at least three generally vertical posts. The kit may include at least three posts each having a longitudinal axis and a cylindrical cross-section along the portion of a length of the posts at which the shelves are to be connected. Each post may have a plurality of grooves therein at predetermined locations which grooves are orthogonal to the longitudinal axis. The kit has at least six sleeves each having a cylindrical interior surface with at least one inwardly extending rib. The cylindrical surface is configured to abut the post and encircle the longitudinal axis during use with the rib configured and located to fit in one of the grooves in the post during use. Each sleeve has a frusto-conical exterior surface and each sleeve further has first and second support tabs extending radially outward from a bottom portion of opposing sides of each sleeve a short distance. Each first and second support tab has an upwardly extending retaining flange extending along an exterior surface of the sleeve and offset therefrom by the support tab from which the retaining flange extends.
The kit also has at least two shelves with each shelf having at least three first-collar parts located around a periphery of the shelf and facing outward from the shelf. Each first-collar part has a frusto-conical interior surface smaller at the top and wider at the bottom and extending around an arc of about 180° along a first-collar part axis which coincides with the longitudinal axis during use. Each first-collar part has a first slot therein extending parallel to the first-collar part axis. Each first slot has a closed end and two opposing sides opening onto a bottom of the first-collar part in which the first slot is located. Each first-collar part and its first slot are sized so the first-collar part fits between one of the retaining flanges and exterior surface of the sleeve while the sides of the first slot fit on opposing sides of one of the first support tabs from which the retaining flange extends. The first slot and first support tab are configured so that the first slot fits snuggly over the first support tab.
The kit also has at least six second-collar parts each having a frusto-conical interior surface that is smaller at the top and wider at the bottom and extending around an arc of about 180° along the first-collar part axis which coincides with the longitudinal axis during use. Each second-collar part has a second slot therein with a closed end and two opposing sides opening onto a bottom of the second-collar part in which the second slot is located with the second slot extending parallel to the first-collar part axis during use. The first-collar part and second-collar parts interlock to define a generally cylindrical interior passage. Each second-collar part and its second slot are sized so the second-collar part fits between one of the retaining flanges and exterior surface of the sleeve from which the retaining flange extends while the sides of the second slot fit on opposing sides of the second support tab from which the retaining flange extends. The second slot and second support tab are configured so that the second slot fits snuggly over the second support tab.
The kit also has interlocking means on each of the first and second collar parts for preventing lateral separation of those interlocked collar parts in a plane transverse to the longitudinal axis during use. The interlocking means may include a male flange having opposing sides and extending outward from each of two opposing sides of the first collar part and extending along a substantial length of each collar part measured along the longitudinal axis. Each male flange has a thickness T between opposing sides of the flange and extends outward a distance between about 3T and 10T. The interlocking means also includes a female channel extending outward from each of two opposing sides of the second collar part and extending along a substantial length of the second collar part measured along the longitudinal axis. Each female channel has an open bottom configured to slidably receive one of the male flanges during use. Each female channel extends along opposing sides of a different one of the male flanges during use.
In further variations of the interlocking collar, each male flange has a trapezoidal shape. Each first collar part is connected to a shelf, the second collar part is connected to a shelf, or both the first and second collar parts are connected to a shelf.
In a still further variation, the interlocking means comprises a first collar part having a top end and bottom end with a distance H1 between the ends measured along the longitudinal axis. The bottom end forms a larger diameter portion of the frusto-conical passage. The first collar part has two first flanges each forming a first juncture with a curved portion of the first collar part as each first flange extends outward from diametrically opposing side of that curved portion of the first collar part. The first flanges extend a distance from the outside of the curved portion between about 3 and 10 times a thickness of the first flange. The first collar part has two, first closed ended slots extending through a thickness of the first collar along a length of the first juncture and opening onto the top end to define two first flanges each having a free upper end separated from an upper portion of the first collar part and each having a lower end joined to a lower portion of the first collar part along the first juncture during use. The first collar part has a third closed ended slot extending from the bottom end along the longitudinal axis and opening onto the bottom end. The third slot is located at about the middle of the curved portion of the first collar part.
This further variation further includes a second collar part having a top end and bottom end with a distance H2 between the ends measured along the longitudinal axis. The top end forms a smaller diameter portion of the frusto-conical passage. The first collar part has two second flanges each forming a second juncture with a curved portion of the second collar part as each second flange extends outward from diametrically opposing side of that curved portion of the second collar part. The second flanges extend a distance from the outside of the curved portion between about 3 and 10 times a thickness of the second flange. The second collar part has two, second closed ended slots extending through a thickness of the second collar along a length of the second juncture and opening onto the top end to define two second flanges each having a free lower end separated from a lower portion of the second collar part and each having an upper end joined to an upper portion of the second collar part along the second juncture during use. The second collar part has a third closed ended slot extending from the bottom end along the longitudinal axis and opening onto the bottom end of the second collar part with the third slot located at about the middle of the curved portion of the second collar part. Each first slot is sized to receive a different second juncture and each second slot is sized to receive a different first juncture when the first and second collar parts are engaged by relative movement along the longitudinal axis. Each third slot is sized to engage a different pair of outwardly extending tabs on the sleeve during use.
In still further variations of this interlocking collar, each first flange is generally parallel to a top portion of the second collar part and each second flange is generally parallel to a bottom portion of the first collar part when the first and second collar parts are engaged. Advantageously, H1 and H2 are about the same. Further, the length of the first slots are about half of H1 and the length of the second slots are about half of H2. The first and second collar parts advantageously have a substantially uniform thickness and the first and second flanges advantageously have a side inclined to the longitudinal axis and in a plane with that axis.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other advantages and features of the invention will be better appreciated in view of the following drawings and descriptions in which like numbers refer to like parts throughout, and in which:

FIG. 1 is a partially exploded perspective view of a portion of a shelf fastened to a collar part and sleeve along with a portion of a locking end frame and collar part, looking along the shelf;

FIG. 2 is a perspective view of the sleeve of FIG. 1;

FIG. 3a is a top perspective view of a first sleeve half;

FIG. 3b is a front plan view of the first sleeve half of FIG. 3 a;

FIG. 3c is a left side view of the half sleeve of FIG. 3 b;

FIG. 3d is a right side view of the half sleeve of FIG. 3 b;

FIG. 3e is a bottom perspective view of the first half sleeve of FIGS. 3a -3 d;

FIG. 4a is a top perspective view of a first sleeve half;

FIG. 4b is a front plan view of the first sleeve half of FIG. 3 a;

FIG. 4c is a left side view of the half sleeve of FIG. 3 b;

FIG. 4d is a right side view of the half sleeve of FIG. 3 b;

FIG. 4e is a bottom perspective view of the first half sleeve of FIGS. 3a -3 d;

FIG. 5a is a top perspective view of the two collar parts of FIG. 1 looking toward the shelf;

FIG. 5b is a bottom perspective of the two collar parts of FIG. 5 a;

FIG. 5c is a top perspective view of the two collar parts of FIG. 5a looking along the shelf;

FIG. 5d is a bottom perspective of the two collar parts of FIG. 5 c;

FIG. 5e is a side view of the two collar parts of FIGS. 5a -5 d;

FIG. 6a is a top perspective view of part of a shelf fastened to a collar part that is fastened to a sleeve and post, and a partial end frame and collar part adjacent ready to be fastened to the sleeve and post, looking along a portion of the shelf;

FIG. 6b is a lower perspective view of FIG. 6 a;

FIG. 6c is a bottom perspective view of FIG. 6a looking toward the shelf;

FIG. 6d is a top perspective view of FIG. 6a looking toward the shelf;

FIG. 6e is a side view of the assembly of FIG. 6 a;

FIG. 7a is the a top perspective view of the assembly of FIG. 6a joined together;

FIG. 7b is a lower perspective view of the assembly of FIG. 6b joined together;

FIG. 7c is a top perspective view of FIG. 7a looking along the shelf;

FIG. 7d is a bottom perspective view of FIG. 7 c;

FIG. 7e is a side perspective view of the assembly of FIG. 6e joined together;

FIG. 8 is a partially exploded view of a shelf with four sleeves and collar parts with an end frame and two collar parts offset from the adjacent sleeves and shelf;

FIG. 9a is a front plan view of a shelving unit with four shelves and four posts, with the back view being a mirror image thereof;

FIG. 9b is a right side plan view of the shelf of FIG. 9b , with the left side view being a mirror image thereof;

FIG. 10 is a perspective view of the sleeve of FIGS. 2-4 with the sleeve parts hinged together;

FIG. 11 is a top plan view of the sleeve of FIGS. 10 and 13;

FIG. 12 is a back plan view of the sleeve of FIGS. 10 and 12;

FIG. 13 is a front plan view of the sleeve of FIGS. 10 and 12;

FIG. 14a is an upper left perspective view of an exterior side of a female collar part having a channel;

FIG. 14b is a perspective view from the opposing side of the female collar part of FIG. 24a , showing an interior side of that collar part;

FIG. 14c is a front plan view of the female collar part of FIG. 14 a;

FIG. 14d is a right side plan view of the collar part of FIG. 14c , with the opposing side being a mirror image thereof;

FIG. 14e is a back side plan view of the collar part of FIG. 14 c;

FIG. 14f is a top plan view of the collar part of FIG. 14 d;

FIG. 14g is a bottom plan view of the collar part of FIG. 14 d;

FIG. 15a is an upper right perspective view of an exterior side of a male collar part;

FIG. 15b is a perspective view from the opposing side of the male collar part of FIG. 15a , showing an interior side of that collar part;

FIG. 15c is a right side plan view of the male collar part of FIG. 15 a;

FIG. 15d is a front side plan view of the collar part of FIGS. 15a and 15 c;

FIG. 15e is a back side plan view of the collar part of FIGS. 15a and 15 c;

FIG. 15f is a top plan view of the collar part of FIG. 15 c;

FIG. 15g is a bottom plan view of the collar part of FIG. 15 c;

FIG. 16a is a right side, upper perspective view of the interlocked male and female collar parts of FIGS. 14a-g and 15a -g;

FIG. 16b is a left side, upper perspective view of the interlocked male and female collar parts of FIG. 16 a;

FIG. 16c is a front plan view of the interlocked male and female collar parts of FIG. 16 a;

FIG. 16d is a left plan view of the interlocked male and female collar parts of FIG. 16 a;

FIG. 16e is a right plan view of the interlocked male and female collar parts of FIG. 16 a;

FIG. 16f is a top plan view of the interlocked male and female collar parts of FIG. 16 c;

FIG. 16g is a bottom plan view of the interlocked male and female collar parts of FIG. 16 a;

FIG. 17a is a perspective view of a sleeve with a male collar part of FIGS. 14a-g on a sleeve of FIGS. 10-12, with a female collar part of FIGS. 15a-15g ready for engagement;

FIG. 17b is a perspective view of the sleeve and collar parts of FIG. 17a fully engaged;

FIG. 18 is a perspective view of a portion of a shelf connected to two male collar parts of FIGS. 15a-15g on opposing ends of the shelf and resting on a sleeve, about to be joined by an end frame having two female collar parts of FIGS. 14a-14g on opposing ends;

FIG. 19a is a perspective view of two, three-tiered, rectangular shelves joined to common, central posts by the collar parts of FIGS. 14-15 with the shelves connected to the male collar parts of FIGS. 14a -14 g;

FIG. 19b is a perspective view of the connection of the shelf with the corner post on the left side of FIG. 19 a;

FIG. 19c is a perspective view of the connection of two shelves with the middle post of FIG. 19 b;

FIG. 19d is a perspective view of the connection of the shelf with the corner post on the right side of FIG. 19 a;

FIG. 20a is an upper left perspective view of an further embodiment showing an exterior side of an upper, interlocking collar part having slots opening downward and showing an exterior of the collar part;

FIG. 20b is a perspective view from the opposing side of the interlocking collar part of FIG. 20a , showing an interior side of that collar part;

FIG. 20c is a front plan view of the collar part of FIG. 20 a;

FIG. 20d is a left plan view of the collar part of FIG. 20 a;

FIG. 20e is a back plan view of the collar part of FIG. 20 a;

FIG. 20f is a top plan view of the collar part of FIG. 20 c;

FIG. 20g is a bottom plan view of the collar part of FIG. 20 a;

FIG. 20h is an upper left perspective view of the collar part of FIG. 20a with the manipulating tab fastened slightly differently;

FIG. 21a is an upper right perspective view of a lower, interlocking collar part having slots opening upward and showing an exterior of the collar part;

FIG. 21b is a perspective view from the opposing side of the lower interlocking collar part of FIG. 21a , showing an inner side of that interlocking collar part;

FIG. 21c is a back side plan view of the lower interlocking collar part of FIG. 21 a;

FIG. 21d is a right side plan view of the lower interlocking collar part of FIGS. 21c and 21 a;

FIG. 21e is a front plan view of the interlocking collar part of FIGS. 21d and 21 a;

FIG. 21f is a top plan view of the interlocking collar part of FIG. 21 d;

FIG. 21g is a bottom plan view of the lower interlocking collar part of FIG. 21 d;

FIG. 22a is an exploded perspective view of one of the upper collar parts of FIG. 21a-21g about to engage a lower interlocking collar part on a sleeve and having tabs and retaining flanges;

FIG. 22b is a perspective view of the collar parts of FIG. 22a , engaged with each other and with a sleeve having tabs and retaining flanges; an exploded perspective view of the upper collar parts of FIG. 31a independent from each other and about to engage lower interlocking collar parts and a sleeve on a shelf;

FIG. 23a is an exploded perspective view of two upper interlocking collar parts of FIGS. 20a-20g about to each independently engage a different lower interlocking collar part of FIGS. 21a-21g each of which is connected to a shelf and that is also connected to a sleeve having tabs and retaining flanges;

FIG. 23b is an exploded perspective view of two, upper interlocking collar parts of FIGS. 20a-20g each connected to opposing ends of an end frame and about to engage a lower interlocking collar part of FIGS. 21a-21g which is connected to a shelf that is also connected to a sleeve having tabs and retaining flanges;

FIG. 24a is a perspective view of two, three-tiered, rectangular shelves joined to common, central posts;

FIG. 24b is a plan view of the connection of two shelves with the middle post of FIG. 24a ; and

FIG. 24c is a plan view of the connection of the shelf with the corner post on the right side of FIG. 24 a.

DETAILED DESCRIPTION

Referring to FIGS. 1-9, and especially to FIGS. 1-2, a connector of the present invention is described as used in a knock-down shelving system. The connector is preferably used in a shelving system that generally includes a plurality of support posts 12 which are preferably cylindrical, that is, that are generally circular in radial cross-section, but which could have other cross-sectional shapes. In the illustrated embodiment of FIGS. 9a, 9b , four such posts 12 are arranged to support one or more shelves 14 at corner assemblies thereof. The shelves 14 are typically wire frame shelves having corners connected to outer collar parts 16 of the connectors 10 to form shelving assemblies which are located at various elevations on the post 12 to form shelving assemblies. The shelves 14 are typically welded to collar parts 16 if the shelves and collars are of metal, but various connecting methods may be used. If the shelves and collars are of plastics, the parts may be integrals molded at the same time, or the collars 16 may be bonded to the shelf 14 by adhesives, ultrasonic bonding or other methods. The shelves 14 are preferably in a plane orthogonal to the longitudinal axis 18.
As used herein the relative terms above and below, upper and lower, top and bottom are with respect to the relative positions along the longitudinal axis 18 of a post 12, which is typically in the vertical direction. The relative terms inward and outward, inner and outer are the relative directions toward and away from that axis 18 when the parts are orientated in the assembled position. These terms are provided with respect to the normal horizontal orientation of shelves and the vertical orientation of posts as shown in the attached figures. The orientation of the shelving unit may change and if so the orientation of the actual unit may be transposed to correspond with the orientation of the figures for easier and consistent understanding.
The collars 16 compress sleeves 20 inward toward posts 12 and are believed to wedge against the sleeves against the post to form a friction lock with the post. The collars 16 are usually split into two parts 16 a, 16 b but need not be so. If split into two parts the collar part 16 a is on the shelving unit 14 while the collar part 16 b is used to further lock the sleeves 20 and shelves in place. The sleeves 20 are formed of two, split sleeve halves 20 a, 20 b which are preferably axially symmetric images of each other as seen in FIGS. 3a-d and 4a-d . The sleeve halves 20 a, 20 b each have an interior surface 22 and opposing exterior surface 24. The interior surface 22 is sized and configured to conform to about half of the outer surface of post 12. In the preferred embodiment post 12 is cylindrical so inner surface 22 is about half of a cylindrical with a diameter about the same as or slightly larger than the outer diameter of post 12. Surface 22 encircles about half the post 12, and preferably slightly less than half. Outer surface 24 is slightly tapered like a cone, narrower in diameter at the top and larger in diameter at the bottom so that the outer surface of sleeve 20 is frusto-conical. A slight taper of about 1-5 degrees is believed suitable, with about 2-3 degrees taper being preferred.
The sleeve halves 20 a, 20 b each have two opposing, first and second sides shown in the figures as generally vertical sides. The arc subtended between each first and second side is slightly less than 180° so the sleeve halves may be squeezed toward each other by the collar parts 16 a, 16 b and squeezed tightly against the post 12 during use.
Each sleeve half 20 a, 20 b has an inwardly extending rib 26 a sized and configured to mate with a corresponding groove 26 b (FIGS. 6, 7, 9) in the outer surface of post 12. While one rib 26 a is shown, more ribs can be used, but preferably few in number and most preferably 2 or 3 ribs. If the sleeve halves have more than one rib 26 a the ribs are spaced apart along a length parallel to axis 18 at regular intervals which correspond to the distance between grooves 26 b in the posts 12. The mating ribs 26 a and grooves 26 b are preferably semicircular in cross-section, but other cross-sectional shapes can be used.
Each sleeve half 20 a, 20 b has at least one support tab 30 extending outward from a bottom portion of the sleeve half and extending radially outward from each of the generally vertical sides, so there are first and second support tabs 30 a, 30 b on each sleeve half. The support tabs 30 preferably extend radially outward a distance D1 about 2-3 mm, but the distance will vary depending on the thickness of the collar part 16 a, 16 b as will become apparent later. The support tabs 30 preferably extend around a portion of the outer circumference of the sleeve a distance D2 of about 3 mm (about ⅛ inch), but that distance will vary with the load capacity to be carried, the materials and other factors as will become apparent later. In the depicted embodiment the support tabs 30 have a height H along axis 18 of about 20 mm (about ⅞ inch), but that distance will vary as described later. The support tabs 30 are preferably molded with the remainder of sleeve 30 and thus have a slight taper with the tabs 30 being larger at the bottom of the sleeve and smaller toward the top of the sleeve. At the bottom of the sleeve the width of each tab 30 a, 30 b is such that it subtends an arc of about 10°. As seen in FIGS. 2-4, the resulting sleeve halves 20 a, 20 b have a bottom portion that is much thicker at the location of the support tabs 30 and retention flange 32.
The outward ends of support tabs 30 extend upward to form a retaining flange 32. The retaining flanges preferably are curved and inclined to be generally parallel with the adjacent portion of the outer surface 24 of the sleeve 20. In the depicted embodiment each retaining flange 32 subtends an arc of about 25-30°. The support tabs 30 offset the retaining flanges 32 from the outer surface 24. In the depicted embodiment there is an increase in thickness of about 3 to 4 times the nominal wall thickness of the sleeve halves 20 a, 20 b. That increased thickness preferably extends from about ⅓ to about ½ the height of the sleeve halves 20 a, 20 b at the location of the support tabs 30. The retaining flanges 32 extend upward a distance of about ⅕ to ⅓ the height of the sleeve 20 measured along axis 18.
Referring to FIG. 2, each of the sleeve halves 20 a, 20 b may have a lip 33 extending along the bottom edge of each sleeve half 20 a, 20 b, preferably along a peripheral circumference corresponding to that of the retaining flange 32. The lip 33 advantageously extends around the entire periphery of the sleeve's bottom and more preferably extends between the inward facing surface of the retaining flange 32 and the facing surface of the sleeve 20. The collar 16 may rest against the lip 33 during use. Alternatively, the lip 33 may extend only between the retaining flange 32 and the adjacent surface of the sleeve 20, being further joined to the outwardly extending support tab 30 a or 30 b. Thus, the support tab 30 may have a larger, first axial length along the straight side of the sleeve and a much reduced axial length along lip 33 which extends from that straight side of the sleeve and curves around the periphery. The lip 33 thus connects the bottom of the sleeve to the bottom of the retaining flange 32 and support tab 30 and forms a hollow area behind the retention flange 32 within which the collar part 16 a, 16 b fits during use and against which the collar 16 may abut during use.
Referring to FIGS. 3a-3e , extending tangentially from the one side of sleeve half 20 a is a locking tab 34. The locking tab 34 is shown as rectangular in cross-sectional shape with a bottom edge of the locking tab 34 adjacent the top surface of the support tab 30 a. The locking tab 34 is thus at about the middle of one substantially straight side of the sleeve 20 a, 20 b. On the opposing substantially straight side of the sleeve 20 ( sleeve parts 20 a, 20 b) is a locking recess 36 configured to receive the locking tab 34. The depicted locking recess 36 is thus rectangular in shape to receive the rectangular locking tab 34, and the locking recess 36 has a bottom adjacent the outwardly extending support tab 30 b. The recess 36 is preferably a slot in the outer surface of the sleeve half 30 a or 30 b sized to receive the locking tab 34.
Referring to FIGS. 4a-4e , the other sleeve half 20 b has a locking tab 34 and locking recess 36 on the opposite sides as does the sleeve half 20 a. Because the mating sleeve half 20 b is axially symmetric with sleeve half 20 a, a detailed description is not provided of the common parts. When the sleeve halves 20 a, 20 b are put together the interior wall 22 of the sleeve defines a cylindrical passage to encircle and abut post 12 during use, and the two locking tabs 34 mate with the locking recesses 36 to hold the parts together.
The locking tabs 34 and mating locking recesses 36 are preferably configured to form a snap-fit or friction fit to releasably hold the sleeve halves 20 a, 20 b together. The locking tabs 34 may be tangential from the curve of sleeve 30, but preferably curves about axis 18 with the same curvature as either of the sleeves 30 a, 30 b and the recesses 36 may have abut walls with a conforming curve. The locking tabs and recesses 34, 36 prevent relative movement of the sleeve halves 20 a, 20 b along the direction of the longitudinal axis 18. In the depicted embodiment, the locking tabs 34 have a cross section about 2 mm thick by about 10 mm high and extend from the substantially straight side of the sleeve halves 20 a, 20 b a distance of about 4 mm. The locking recesses are preferably slightly deeper than the length of the locking tabs 34, with a depth of about 5 mm believed suitable when the locking tab 34 extends about 4 mm from the straight side of the sleeve.
Referring to FIGS. 1-2, when the two half sleeves 20 a, 20 b fit together the interior surface 22 defines an interior, cylindrical passage sized to encircle and abut against post 12, with the outer surface forming a frusto-conical surface with support tabs 30 and retaining flanges 32 on opposing sides of the sleeve 20. The support tabs 30 a, 30 b of each sleeve 20 a, 20 b abut each other along a substantially vertical plane containing the longitudinal axis 18. The interlocking locking tabs 34 and recesses 36 hold the sleeve halves together and restrain slippage along the generally vertical sides and axis 18. The abutting support tabs subtend a combined arc of about 10° at the bottom of the sleeves 30 a, 30 b and extend about 20 mm along axis 18, while the retaining flanges 32 subtend an arc of about 20° from axis 18, and extend from the bottom of sleeve 30 upward a distance of about 30 mm. These dimensions are for a post 12 having a diameter of about 25 mm, with sleeve 20 made of ABS, for a shelf having a load capacity of about 100 pounds.
Referring to FIGS. 1 and 6-8, the collar parts 16 a, 16 b are configured to mate with the sleeves 20 and squeeze them against the posts 12 as well as fitting into the offset space between the retaining flanges 32 and the sleeves, with the collar parts resting on the tabs 32. The collar parts 16 a, 16 b have a frusto-conical wall, or at least an inside that has a tapered, frusto-conical shape that is narrower in diameter at the top and wider at the bottom. The inclination of the frusto-conical wall is preferably about the same as that of the outer surface 24 of the sleeve 20, or slightly more. Each collar part 16 a, 16 b has substantially straight sides preferably extending along a plane containing longitudinal axis 18 edges. The opposing sides of each collar part 16 may subtend an arc of about 180° or slightly less. These opposing sides may also be referred to as distal sides of each collar part.
Each collar part 16 a, 16 b has a slot 38 with a closed end 40 and two parallel sides 42 extending to and opening toward the bottom of the collar part 16 a, 16 b. The slot is preferably at about the middle of the wall forming the collar part 16, about half way between the opposing, straight sides of the collar part. For the above described sleeve 20 the slot may have a width of about 5-6 mm and a height of about 8 mm, with the collar part having a height of about 40 mm and a thickness of about 2 mm when made of steel. The slot shape and size will vary as needed to conform to the shape of support tabs 30 a, 30 b as the purpose of the slot is to hold the tabs 30 together, preferably tightly together.
The width of the slot between the opposing sides 42 is preferably selected to correspond to the circumferential width W of the two abutting support tabs 30 measured in a plane orthogonal to the longitudinal axis 18, so that the sides 42 fit over and preferably very close to the sides of the support tabs 30. The sides 42 of the slot straddle the abutting pair of support tabs 30 with the end 40 of the slot 38 resting on the top of the abutting pair of support tabs 30. The sides 42 are shown as straight, parallel and vertical as the abutting pair of support tabs 30 have straight, vertical sides. The sides 42 could be slightly tapered with the spacing narrower at the closed end 40 of slot 38 and further apart at the open end, preferably with the taper being about the same as that of the inclination angle of the frusto-conical wall of collar part 16 a, 16 b, in which case the abutting sides of the support tabs 30 preferably also have a matching inclination. Thus, if the width W of the abutting support tabs 30 a, 30 b increases from the top to the bottom of the support tabs, with the width W smaller at the top and larger at the bottom, then the sides 42 of the slot also increase in a corresponding manner. Advantageously, the increase in width may be slightly different to create a slight interference that resiliently urges the adjacent support tabs 30 a, 30 b toward each other and preferably so the tabs abut each other.
Likewise the shape of the end 40 of the slot 38 preferably conforms to the shape formed by the top of the pair of support tabs 30 abutting that slot end 40. The wall forming the collar part 16 a, 16 b is sized so that it fits in the offset or gap between the retaining flange 32 and the exterior surface 24 of the sleeve 20 which offset is formed by support tab 30. The slot end 40 may thus rest against the top of the abutting support tabs 30 a, 30 b while the bottom of the collar part 16 a, 16 b adjacent the slot rest against the lip 33. The lip 33 is thus advantageously located relative to the dimensions of the support tabs 30 and collar part 16 a, 16 b and slot end 42 so that the bottom edge of the collar part adjoining sides 40 of the slot 38, abut or rest on the lip 33 during use. The collar part 16 advantageously rests continuously against lip 33 during use, but may abut the lip 33 only when the load on the collar part 16 is high.
The collar 16 may have a collar part 16 a connected to a shelf 14 (FIG. 1), or a part 16 b connected to a locking end frame 44 (FIG. 8) having a collar part 16 on each end but not connected directly to a shelf. Alternatively, referring to FIG. 1, the collar part 16 b may have a manipulation tab 46 extending outward from the collar part 16 a, 16 b a distance sufficient to allow a user to push on the manipulation tab 46 to install the collar part, or to pull upward on the manipulation tab to release it from the mating sleeve 20. Also, each collar part 16 a, 16 b may be separate, without any connecting frame 44, so each collar 16 may be separately locked in position. In actual use a user may also strike the manipulation tab with a tool such as a hammer to install or tighten the collar part, or to loosen or unfasten the collar part. The manipulation tab 46 may take diverse forms and is shown as a portion of a tube with its axis aligned with axis 18, fastened to the outer surface of the collar part 16 b. The manipulating tab 46 is advantageously configured so as not to have sharp edges or protrusions as would snag clothing or cut a person's hands.
In use, the two sleeve halves 20 a, 20 b may be snapped around a vertical post 20 with the locking tabs 34 mating with the locking recesses 30 to hold the parts together. The sleeve halves 20 a, 20 b are located along the length of post 12 so the rib or ribs 26 a in the sleeve mate with a corresponding groove 26 b in the post at the height or location to which it is desired to fasten the shelf 14. All corners of the shelf 14 are preferably at the same height in order to avoid twisting one or more connections. As needed, the sleeve 20 is rotated around the post 12 so each pair of abutting support tabs 30 extends along the direction of a shelf edge or side, pointing toward one of the other corner posts to which the shelf 14 will be attached. A shelf 14 with a collar part 16 a is then mated with the sleeve 20 such that the slot in the collar part 16 a is fit over one pair of abutting support tabs 30 until the bottom 40 of the slot 38 rests on top of the abutting support tabs and the sides 42 of the slot straddle those abutting support tabs, with the body of the collar part surrounding the slot fitting between the retaining flange 32 and the adjacent portion of the outer surface 24 of the sleeve. The other corners of the shelf 14 are similarly attached to other posts 12. That connection leaves one free pair of abutting support tabs 30 extending outward from the sleeve. Another collar part 16 a on a shelf 14 may be similarly attached to that free pair of abutting support tabs. Alternatively, an end frame 44 may be connected in a similar manner with the slot of each collar part 16 fit over the abutting pair of support tabs. As a further alternative, a single collar 16 completely encircling the post may be placed over the free pair of abutting end tabs 30.
The parts may be removed and the shelves taken off the posts 12 by reversing the order of above described steps. Thus, a user may pull upward on the collar part 16 a, 16 b using manipulating tab 46, or pull upward on the locking bar or end frame 44, or pull upward on a shelf 14 to disengage the slot in a collar part from the paired support tabs 30. Once all collar parts 16 a, 16 b are removed from a sleeve 20, the sleeve halves 20 a, 20 b may be pulled apart and removed from the post.
When a collar part 16 a, 16 b is mated with an abutting pair of support tabs 30 the opposing sides 42 of the slot keep the sleeve halves 30 a, 30 b from separating. A tight fit is preferred between the slot sides 42 and the adjacent and preferably abutting sides of the support tabs 30 a, 30 b. As the end 40 of the slot 38 in the collar part abuts the top of the abutting pair of support tabs 30 the support tabs support the weight of shelf 14 and items placed thereon. As the tapered sides of the collar part 16 a, 16 b mate with the tapered sides of the sleeve 20, each collar part wedges against the sleeve 20 and urges the sleeve toward the post for a frictional grip, and urges the ribs 26 a into mating grooves 26 b. As the weight on the shelf 14 increases the gripping forces on the collar part 16 a, 16 b and sleeve 20 increase through the inclined surfaces of the collar part 16 a, 16 b and sleeve 20. But the abutting support tabs 30 reduce the wedging force the collar part 16 a, 16 b exerts on the sleeve 20. Thus, the compressive force the collar part exerts on the sleeve is not as large as in prior art designs. The frusto-conical shaped inner surface of collar parts 16 a, 16 b thus mate with the correspondingly shaped frusto-conical outer surface of sleeve 20 to urge the sleeve against the post 12 during use. The mating parts of the collar parts 16 a, 16 b and sleeve halves 20 a, 20 b advantageously have the same slope or a slight interference fit, with slopes of about 2-10 with 2-5 degrees being preferred suitable and interference fits formed by slopes of 1-3 degrees difference in slope and these fits are used herein to define the preferred mating of these parts. The retaining flange 32 helps prevent the collar part 16 a, 16 b from slipping off the support tabs 30 and helps prevent the collar part 16 a, 16 b from moving laterally in the general plane of the shelf, which is usually horizontal.
It is believed advantageous to have sides 42 of the slot in the collar part cooperate with the abutting sides of the pair of support tabs so that the collar part urges the abutting pair of support tabs 30 a, 30 b together. This may be achieved by having each sleeve half 30 a, 30 b extend slightly less than 180 degrees around the post 12 so that a slight gap is formed between the straight edges of the sleeve halves and between the adjacent support tabs 30 a, 30 b when the sleeve halves are snapped onto the post 12. The sides 42 of the slot in collar part 16 a, 16 b may then resiliently urge the support tabs 30 a, 30 b toward each other until they preferably (but optionally) abut thus resiliently urging the bottom portion of the sleeve 30 against the post 12. Preferably a rib 26 a is located inward of the support tabs 30 a, 30 b and this circumferential tightening by the slot sides 42 urging the support tabs together ensures a tight connection between the sleeve 30 and post 12 at the circumferential location of the support tabs, and ensures a tight connection between the rib 26 a and groove 26 b.
Because the sleeves 30 a, 30 b may be snapped onto the post 12 at any suitable location and the collar need not pass along the length of the post in order to connect to the sleeve 30, the shelves 14 may be connected in any order to the posts 12. No bottom-up assembly is required. Shelves may be inserted between two adjacent shelves without removing the upper shelves. The ease of assembly is believed to be superior to prior art designs.
The collars 16 are preferably split collars having first and second parts 16 a, 16 b each of which do not extend more than 180° around the circumference of the posts 12 and preferably extend about 178-179.5° around the circumference of the post. But the collar parts 16 could extend further and enclose a majority of the circumference of the post 12 and sleeve 30, particularly for collar parts connected to shelves 14. If so, the other collar part 16 engaging the other pair of abutting support tabs 30 would have a correspondingly smaller circumferential size so as to avoid the sides of the collar parts 16 a, 16 b overlapping or otherwise preventing a tight clamp to the post 12. Smaller sized collar parts 16 b are believed suitable for collar parts on the end frames 44 or single collars 16 not connected to a shelf or an end frame but used to lock the free pair of abutting support tabs 30 and keep them from splaying and tightening the connection to the post.
The use of a collar part encircling about 185°-270° of the circumference of the post 12 and sleeve 30 is believed possible, with the other locking collar part encircling the remaining portion of the 360° circumference. If the collar part 16 a, 16 b encircles much more than about 185°-190° of the circumference, then the collar part may no longer be flexible enough to allow opposing sides of the collar part to spread apart to fit around the post 12 from the side, and may require the collar part to be positioned by sliding it axially along the length of the post 12 and axis 18.
The connector 10 can be used in various other types of support systems, such as cabinets, closets, rolling carts, rolling racks and the like, with a shelving system being only one example. Moreover, the connector 10 can be used in conjunction with many shelf embodiments and is not limited to use with a corner of a shelf, or for that matter, a corner of any supported member.
The sleeves 20 a, 20 b may be made of a suitable plastic. ABS, polyethylene and polyurethane are believed suitable. The sleeves are preferably molded as a single piece of material to form an integrally molded part. The posts 12, collar parts 16 a, 16 b and shelves 14 are preferably made of metal, but one or more of them may be made of a sufficiently strong plastic material. Depending on the weight which each shelf 14 or shelving unit is designed to support, the dimensions of parts and material used will vary.
A simplified shelving unit would include four corner posts 12, at least one and preferably more shelves 14 with collar parts 16 of any type as described herein at each location on the shelf (generally corners) where the shelf is to connect to the post 12. For a rectangular shelf 14 with four collar parts 16 a, 16 b, one at each corner to connect to four posts, two end frames 44 would be needed for each shelf, or four single collar parts 16 a, 16 b for each shelf. A shelving kit may be provided that preferably includes those parts and more preferably includes two, three, four, five or six shelves 14 with corresponding numbers of collar parts 16 a, 16 b on each shelf, and twice the number of end frame connectors 44 as there are shelves (or four times the number of single collar parts 16 a, 16 b), and four times the number of sleeves 20 as there are shelves.
A kit may include the above combination of parts and combinations thereof. Thus, a simple shelving kit may have two shelves 14, which if rectangular in shape have a collar part 16 a of any type described herein at each corner of the shelf. The kit would further include eight sleeves 20 and eight collar parts 16 b of any type described herein that are either separated, or with pairs of collar parts 16 b joined to form end frames 44. Each additional rectangular shelf added to the kit would preferably include four collar parts 16 a, four collar parts 16 b and four sleeves 20. If two shelving units are joined horizontally together by having two shelves 14 with two collar parts 16 a at one end fasten to the same two posts 12, then the number of end frames 44 may be reduced by half, as may the number of single piece collars that completely encircle the post, if such single piece collars are used instead of end frames 44 or individual collar parts 16 b.
The offset provided by extending tabs 30 a, 30 b is sized to form a gap between the locking tab 34 and the adjacent outer surface 24 of the sleeve 20 in order to snugly receive the mating portion of collar part 16 a, 16 b. A very slight interference fit is believed acceptable but undesirable. On the other than, a loose fit is undesirable. Thus a clearance of less than about 1 mm is believed desirable. The offset will vary with the materials of which the parts and shelves are made, and the load to be carried on the shelves and posts. Likewise, the dimensions of the sleeves and parts thereof will vary with the materials and loads to be carried by the parts.
The collar parts 16 a 16 b may be interlocked together to hold them together and clamped to the sleeve 20 to prevent separation of the sleeve halves 20 a, 20 b and to keep the shelf 14 in position along the axis 18 of the post 12. The interlocking of first and second collar parts 16 a, 16 b to prevent relative movement in the lateral plane to axis 18 is preferably achieved by interlocking means such as a male and female channel lock or a slotted interlock as described herein.
Referring to FIGS. 10-13, the sleeve halves 20 a, 20 b may be joined together by one or more, but preferably less than three, hinges 80. The hinge 80 is preferably a flexible hinge that repeatably flexes with ease rather than a pinned hinge with multiple, inter-locking segments that rotate a hinge pin. The hinges 80 are preferably connected to the support tabs 30 and/or retaining flanges 32. In the depicted embodiment two hinges 80 are used to join two adjacent support tabs 30 a, 30 b that abut each other or face each other during use. Thus, each of the two hinges 80 has a first end connected to support tab 30 a of sleeve half 20 a and has a second end connected to support tab 30 b of sleeve half 20 b. The depicted hinges 80 are preferably made of a flexible material to allow the sleeve halves 20 a, 20 b to repeatedly open and close around post 12.
Advantageously, the hinges 80 are made of plastic and of the same material as the sleeve halves 20 a, 20 b, with the hinges 80 being integrally formed with the sleeve halves 20 a, 20 b by injection molding to form a unitary part of the same material. The hinges 80 are shown with a rectangular cross-section with the long axis of the rectangle generally parallel with axis 18 during use. The hinges are advantageously parallel to the abutting faces of the supports 30 a, 30 b to which the hinges connect so that the hinges bend along a line parallel to the abutting faces of the supports 30 and allow the sleeve halves 20 a, 20 b to rotate about an axis parallel to those abutting faces of support tabs 30 a, 30 b.
Since the support tabs 30 a, 30 b face each other and preferably abut each other during use with the locking tabs 34 engaging the locking recesses 36, the hinges 80 flex sufficiently to allow that configuration, contact and locking engagement. Each support tab 30 a, 30 b preferably has a recess 82 in the exterior side of the support tab 30 at the location where each hinge 80 connects to each support tab. Advantageously, the recess 82 extends completely around the hinge 80 so as to completely encircle or completely surround the juncture of the hinge with the support tab 30. The recess 82 has a uniform depth so the hinge 80 extends from the surface of the recess 82. The depth of the recess 82 between the hinge 80 and the abutting face of support tab 30 allows the hinge to fit into the recess and reduces the deformation of the hinge. Preferably, the hinge has a thickness “t” in its thin dimension and the recess 82 has a depth of about 0.5t to t, so that the hinge can lay flat in the recess when the sleeve halves 20 a, 20 b join to form sleeve 20, or at least lay flat at the face of the abutting support tabs 30 a, 30 b. The depth of recess 82 is preferably selected so that the thickness of the hinge 80 does not prevent the faces of the support tabs 30 a, 30 b from abutting. By having the recess 82 surround or encircle the hinge 80, the hinge 80 bends uniformly in opposing directions along the axis about which the hinge 80 flexes during use and that is believed to reduce stress on the hinge as it bends.
The recess 82 is configured to allow the hinge 80 to fit within the recess, preferably so the hinge does not extend beyond the adjacent outer surface 24 of the sleeve 20 when the sleeve halves 20 a, 20 b are interlocked by locking tabs 34. As described above, a locking collar 16 with an inner surface conforming to the frusto-conical (or other) tapered shape of the outside of the sleeve 20 and if the hinge 80 extends about the outer surface of the sleeve then hinge cold impede a tight fit of the sleeve and collar. Thus, the hinge 80 fits within the recess 82 so the outer surface of the hinge 80 does not extend above the outer surface of the sleeve 20 defined by the other sleeve parts. A slight extension of about one mm or less may be workable if the sleeve 20 is made of a deformable plastic or polymer material, but that is not desired. Thus, the hinge 80 fits within the recess 82 so the outer surface of the hinge 80 is at about the same surface as that of the remaining portions of the sleeve 20 when the sleeve is on the post 12. By using a recess 82 in each support tab 30 a, 30 b to receive the hinge 80 when the sleeve halves 20 a, 20 b are interlocked the outer surface of the hinge is at or preferably slightly below the outer surface 24 of the sleeve 20 and sleeve parts 20 a, 20 b when the parts are interlocked for use. Thus, the hinge 80 does not prevent the collar 16 from fitting snuggly over the sleeve 20. Because the inside of the collar is configured to mate closely with the outside of the sleeve, a protruding hinge 80 could interfere with the mating of the collar and sleeve, or the collar will deform the hinge and damage or destroy the hinge's function. A slight protrusion at the location of the hinge can be tolerated if the hinge material is sufficiently deformable as to allow the hinge to open and close at least a few times after being deformed and hold the parts together, and this slight protrusion is encompassed within the meaning of having the outer surface of the hinge at or adjacent to the surface of the sleeve or sleeve parts joined by the hinge. This slight protrusion is also within the meaning of having a hinge with an outer at adjacent to the outer surface located at the surface of the first and second tabs that are hinged, adjacent the location of the hinge.
As best seen in FIGS. 10-13, the hinge 80 connects to each support tab 30 a, 30 b at a location spaced slightly inward from the abutting face of the support tab 30 to which the hinge is joined. The hinge line along which the hinge 80 and connected support tabs 30 a, 30 b rotate is preferably at about the outer surface 24 of the support tabs 30 or advantageously within 1-3 mm of that outer surface. A connection at or outward of the outer surface 24 of the sleeve halves 20 a, 20 b is believed suitable, but less preferred. An offset of about 1-5 mm from the abutting face of support tab 30 to the centerline of the hinge 80 is believed suitable with an offset of about 2-3 mm being preferred. A hinge thickness of about 1-3 mm is believed suitable and a hinge length of about 2-8 mm is believed suitable, with a length of about 2-3 mm being preferred. A shorter length on the hinge 80 makes the hinge stiffer and the stiffness has the advantage of resiliently urging the sleeve halves 20 a, 20 b into an open position when the latches 34 are not engaged with the latching recesses 36 and that is believed desirable. But a shorter length of the hinge 80 also increases stress as the hinge bends to allow the sleeve halves 20 a, 20 b to engage and form sleeve 20 engaging the post 12 during use. The dimensions of the preferably rectangular cross-section of the hinge 80 also affect the stiffness, flexibility and stress of the hinge. Hinge dimensions providing a suitable compromise of flexibility, opening force and stress can be determined given the present disclosure.
The hinge(s) 82 have the advantage of avoiding losing one of the sleeve halves 20 a, 20 b during shipping or use. The hinge(s) 82 also connect mating parts and avoid potential confusion in matching sleeves halves 20 a, 20 b during assembly and use. By forming the hinge(s) 80 during formation of the sleeve halves 20 a, 20 b a unitary part can be formed of a single piece of material and that ensure material uniformity, strength and performance. The unitary structure also simplifies sorting the parts for shipment, simplifies assembly and simplifies use.
Because the hinge 80 is preferably located in and surrounded by recess 82 the hinge or hinges are preferably located in the support tabs 30 a, 30 b. But the hinges could be located in the retaining flange 32, using the same construction described above. If a hinge 80 is connected to the retaining flange 32 the recess 82 may reduce the strength of the flange 32 and increase its flexibility. Depending on the strength and flexibility needed for a particular retaining flange the recess 82 may not affect performance and suitable design can be achieved if a recess 82 is desired to be used. Alternatively, because the recess 82 is optional, the hinge 80 could connect the sleeve halves 20 a, 20 b without a recess, with the hinge location and length being varied to achieve a desired connection of the parts to which the hinge is connected, but with an outer surface of the hinge forming a substantially continuous surface with and not protruding above the outer surface the support tabs 30 or flanges 32 connected to the hinge(s).
Because the hinge 80 connects mating parts the assembly of a shelving unit is simplified and users will not attempt to mate two like sleeve parts such as mating sleeve half 20 a with 20 a, or sleeve half 20 b and 20 b. Also, because the mating parts are connected by the hinge 80 parts will not become separated during shipment, assembly or disassembly. Because the hinge line at the surface or slightly recessed or at least does not extend much beyond the outer surface 24 of the sleeve 20, the mating between the collar 16 and sleeve 20 is not disrupted by the hinge 80.
Referring to FIGS. 14-18, the channel lock mechanism is formed on the collar parts 16 a′, 16 b′. The collar parts will have mating shapes and oriented in opposing directions along axis 18 during use. Each collar part 16 a′, 16 b′ may have the following shape recognizing that during use the other collar part will have a different, mating shape and orientation described later. Either one of the first and second collar parts 16 a′, 16 b′ could be fastened to the shelf 14 so for ease of reference they are referred to as 16 a′, 16 b′ when describing the first collar part, and referred to as 16 b′, 16 a′ when describing the second collar part. The first collar part is preferably the one connected to the shelf 14 during use.
The channel lock mechanism may have an axially elongated outwardly extending male projection 50, shown as a flange on a first collar part 16 a′, 16 b′ and described herein as flange 50. The flange 50 extends along a substantial axial length of each side or distal edge of the collar part 16 a′, 16 b′ on which it is located, joining the typically curved exterior body of the collar part 16 a′, 16 b′ along juncture 49. The flange 50 preferably extends along more than half that length, and preferably extends more than 80% of that length and more preferably extends about the full length of the (vertical) side or distal edge of the collar on which the flange is located. The flange 50 thus preferably extends outward from the side of the semicircular body portion of the collar part, with the juncture 49 located at the transition between the flange and the curved body part. The flange 50 preferably extends radially outward relative to the longitudinal axis 18 during use so the flange 50 is parallel with the axis 18. The flange 50 is preferably short in the outward direction, preferably about 2-10 times the thickness of the flange and more preferably about 2-5 times the thickness of the flange. As used herein, the outward direction means away from the longitudinal axis 18 when the parts are in their use configuration.
Each outwardly extending flange 50 has two opposing side faces 51 a, 51 b joined by an outward facing distal edge 51 c. The edge 51 c is generally aligned with the post axis 18 during use, but may be slightly inclined relative to that axis, usually with the upper end closer to the axis than the lower end during use. The front face 51 a faces a direction toward the main portion of the mating collar part while the rear face 51 b faces away from the mating collar part. As the distal edges of the collar parts 16 a′, 16 b′ are preferably aligned with the axis 18 during use, the flange 50 generally extends vertically relative to the floor during use when the shelves 14 are horizontal. Thus, the first collar 16 a′, 16 b′ has two flanges 50, one extending along each of the opposing distal ends of the collar and forming juncture 49 with the collar.
The male flange 50 is received in a female channel 52 configured to enclose the sides and distal edge of the flange 50. The female channel 52 is connected to the second collar part, 16 b′, 16 a′. The depicted channel 52 has a cross-sectional shape that has a “U” shaped cross section with two outwardly aligned and preferably parallel sides 54 a, 54 b joined by a distal edge 56. The first side 54 a extends outward from the collar part 16 with the second side 54 b extending inward and with the distal edge 56 joining the outward edges of those sides. The sides 54 a, 54 b with end 56 form a channel having a U-shaped cross section with an elongated opening facing the axis 18 with the channel having open ends at the top and bottom of the collar part. The body forming channel 52 preferably extends radially outward relative to axis 18 when the parts are assembled for use so as to place the faces 54 a, 54 b general parallel with the male flange 50 so as to enclose the flange. Closed ended slot 38 extends into the bottom portion of the collar part and opens onto the lower end of the second collar part 16 b′, 16 a′. The slot 38 is preferably centered between the two channels 52 and extends in a direction along axis 18 during use.
The channel 52 preferably has spaced apart sides 54 a, 54 b forming a narrow slot or groove within which the male flange 50 is enclosed during use. The channel side 54 a is located toward the mating collar part while the channel side 54 b is located away from the mating collar part and closer to the main body of the collar part from which it extends. The inside surfaces of the sides 54 a, 54 b face each other. Each channel side 54 a extends from an opposing, distal circumferential end of the collar part, and forms juncture 53 where it joins that collar part. The channel side 54 a preferably extends radially outward from a side of a semi-circular collar part, with juncture 53 extending along the transition from the curved body portion of the collar part and the side 54 a. The channel 52 has to receive the flange 50 so the sides 54 a, 54 b extend outward more than the flange 50. Thus the sides 54 extend in the outward direction, a few millimeters more than the flange 50. The sides 54 a, 54 b allow the male flange 50 to pass closely between them are thus spaced apart a distance greater than the thickness of the flange 50, but preferably close enough to form a snug fit and preferably with no gap greater than a few mm. Thus, the female channel 52 extends outward from each of two opposing sides of a collar part and extends along a substantial length of that second collar part measured along the longitudinal axis 16. Each female channel 52 has an open bottom configured to slidably receive one of the male flanges 50 during use, with each female channel 52 extending along opposing sides 54 a, 54 b of a different one of the male flanges during use. The second collar part 16 b′ is preferably formed of a single piece of material, such as metal bent to the desired shape or molded plastic. The channel 52 preferably forma s U-shaped or C-shaped cross-section to as to enclosed opposing sides of the male flange 50 and restrain relative movement of the flange and channel in the lateral plane or direction.
In use, the first collar part 16 a′, having male flange 50 is preferably fastened to the shelf 14 and the collar part 16 a′ is slid downward onto the sleeve 20 on a post 12 so the slot 38 and slot sides 42 and slot end 40 in the collar part 16 a′ engage two support tabs 30 on different sleeve parts 20 a, 20 b to hold them together and preferably also rests on the lip 33 of the sleeve parts. The second collar part 16 b′ is then placed along axis 18 and moved axially downward so the female channel 52 slides over the male flange 50 and also the slot 38 engages the two support tabs 30 of the two joined sleeve portions to hold them together and preferably also rests on the lip 33 of the sleeves. If the shelf 14 is connected to the second collar part 16 b′ that contains the female channel 52, the assembly sequence is the same except that after the second collar part 16 b′ connects the shelf 14 to the post, then the first collar part is moved along axis 18 to slide the male flange 50 into the female channel 52.
Placing the male flange 50 in the female channel 52 interlocks the collars 16 a′, 16 b′ to both clamp the sleeve parts 20 against the post 12, and to further inhibit separation of the sleeve parts and collar parts. Preferably, when the male flange 50 is received in the female channel formed by opposing sides 54 a, 54 b, the face 51 b of the male flange 50 contacts the inner face of side 54 a. It is useful to have the face 51 b of the male flange 50 contact the inner face of the side 54 a of channel 52 as that can hold the parts together and preferably urge the parts together, but the parts must easily and removably interconnect. Thus, while the side 54 a is preferably parallel to the male flange 50, the side 54 b need not be parallel to that flange and may be slightly curved or inclined to form a slight interference fit as the male flange 50 fits into the channel 52.
The flange 50 contacts the sides 54 a, 54 b of the channel 52 to prevent relative movement of the parts from moving laterally apart along an axis perpendicular to the faces of the flange 50 and sides 54. The contact between the outward facing edges 51 c, 56 of the flange 50 and channel 52 prevents the relative movement of the parts along the radial direction of the flange 50 and sides 54. Combinations of those contacting parts inhibit relative separation of the collar parts 16 a′, 16 b′ and sleeve parts 20 a, 20 b along intervening directions. The retaining flanges 32, sleeves 20 and post 12 keep the parts from moving in the plane orthogonal to axis 18. The ribs and grooves 26 a, 16 b on the pole and collar restrain movement along the pole 12 and its axis 18.
Because the flange 50 and channel 52 can each extend the axial length of the respective collar parts 16 a′, 16 b′, an increased length of the interlocking parts that resist separation is achieved. Because the flange 50 has the same thickness as the collar the flange forms a strong and stiff resistance to separation of the interlocked collar parts and the sleeve parts held inside the collar parts. Because the sides 54 a, 54 b and distal end 56 of channel 52 preferably have the same thickness as the collar from which the sides and end extend they form a strong and stiff resistance to separation of the interlocked collar parts and the sleeve parts held together by the interlocked collar parts.
The flange 50 and channel 52 preferably extend for about the same axial distance relative to axis 18 during use of the parts, and are aligned to mate and contact each other during use. But one could be shorter or the other could be longer, so for example, the male flange 50 may extend less than the full length of the first collar part measured along axis 18 during use, while the female channel 52 may extend the full length of the second collar part, or the female channel 52 may extend less than the axial length of the first collar part. The relative lengths could be reversed. Thus, for example, the male flange 50 could extend from the top of the collar part 16 a′ toward the bottom, but end before the bottom of the collar part, preferably between about 60-90% of the length of the first collar part, while the female channel 52 may extend the full length of the second collar part 16 b′ or extend about 60-90% of the length of the second collar part, from the top of the second collar part toward its bottom.
The collar parts 16 a′, 16 b′ have inclined sides to form a frusto-conical passage through the joined collar parts which passage extends along axis 18 during use, with each collar part extending about half way around that axis during use. Referring to FIGS. 14a-14g and 15a-15g , the collar parts 16 a′, 16 b′ preferably have a uniform thickness between the interior and exterior surfaces so the outside surface curving around axis 18 has a frusto-conical shape parallel to that of the inside surface. The male flange 50 preferably has a distal edge 51 c that is preferably parallel to the axis 18 while the juncture with the curved body of the part is inclined parallel to the frusto-conical surface which causes the flange 50 to have a trapezoidal shape with the distal edge 51 c and juncture with the curved portion being non-parallel, while the top side of the flange 50 is slightly longer than the bottom side an parallel to that bottom side. The same applies to the channel 52, which can have a distal edge 56 parallel to the axis 18 while side 51 a joins the curved portion of part 16 a′ along an inclined juncture parallel to the inclined, frusto-conical surface, resulting in sides 54 a, 54 b having a trapezoidal shape with a top side slightly longer than the bottom side but parallel.
The male flange 50 and female channel 52 described herein provide interlocking collar means for restraining relative movement of the collar parts 16 a′, 16 b′ in the lateral plane of the shelving, or in a plane orthogonal to the axis 18 during use, or in the lateral direction relative to the shelving 14 or post 12. In this embodiment the manipulating tab 46 is shown as a wire loop with legs aligned with the exterior sides of the collar part 16 and fastened thereto with the tab extending outward so a person's finger can grab it to manipulate the collar. The loop formed by the tab 46 is preferably large enough so a person's fingertip can fit through loop between the collar part 16 and the tab. The legs of the wire loop are preferably aligned with the longitudinal axis 18, and may extend along that axis in either direction as shown in FIGS. 20a and 20 h.
The second collar portion 16 b′ is used to lock the sleeve parts 20 a, 20 b together and to interlock with the first collar portion 16 a′ as described above. The second interlocking collar portion 16 b′ may be used independently, or a different collar portion 16 b′ may be connected to each opposing end of end frame 44 to interlock a pair of first interlocking collar portions 16 a′ as shown in FIG. 18. The second interlocking collar part 16 b′ is orientated so the larger diameter of the conical shape of the interlocking collar portion 16 b′ is downward and the smaller diameter is at the top during use so as to mate with and wedge sleeve parts 20 a 20 b against post 12 during use and to interlock with the first interlocking collar part 16 a′ to form a frusto-conical structure encircling a split sleeve 20 to clamp it against the post 12 during use. The interlocking portions 16 a′, 16 b′ not only interlock, but the closed slot 38 in each interlocking part engages the support tabs 30 and retaining flanges 32 as described above. The interlocking collar parts 16 a′, 16 b′ may thus be interlocked together to hold them clamped to the sleeve 20 to prevent separation of the sleeve halves 20 a, 20 b and to keep the shelf 14 in position along the axis 18 of the post 12. The interlocking of first and second collar parts 16 a′, 16 b′ is preferably achieved by locking means such as a male and female channel lock or a slotted interlock as described herein.
Referring to FIGS. 20-22, a further embodiment of a slotted interlock mechanism is shown to interlock the collar parts 16 a 16 b together to hold them clamped to the sleeve 20 to prevent separation of the sleeve halves 20 a, 20 b and to keep the shelf 14 in position along the axis 18 of the post 12. Referring first to FIG. 21 (FIGS. 21a-21g ), the first collar part 16 a″ has a frusto-conical body with a flange 60 extending outward from each side or distal edge of the collar part 16 a″. The frusto-conical body part 16 a has a larger diameter lower edge and a smaller diameter upper edge. In this further embodiment the flange 60 extends outward, preferably radially outward, from each side or distal edge of the collar part 16 a″. The flange 60 extends along a length of each side or distal edge of the collar part 16 a″, preferably along substantially the full axial length of the side or distal edge with juncture 59 extending along the transition between the curved and preferably semi-circular body portion of the collar part and the outwardly extending flange 60. Closed ended slot 38 extends into the bottom portion of the collar part 16 a″ along juncture 59 and opens onto the lower end of the collar part 16 a″. The slot 38 is preferably centered between the two flanges 50 and extends along axis 18 during use. Each flange 60 has two opposing sides or faces 61 a, 61 b and a distal edge 61 c. The side 61 a is on the same side of the collar part 16 a″ as the interior of the collar part and side 61 b is on the same side of the collar part 16 a″ as exterior side. A closed-end slot 62 extends along a length of the normal juncture 59 of the flange 60 to the side of distal edge of the collar part 16 a″ to which the flange 60 is connected. In the depicted orientation the slot 62 extends upwardly. The slot 62 preferably extends about half the axial length of the collar part 16 a″, but may extend shorter or longer, preferably varying within about 15% of the length of the collar part 16 a″.
The slot 62 separates a portion of the flange 60 from the collar part 16 a″ to form a free end 64 on the flange 60, with the base of the flange 60 being connected to the collar part 16 a″. Because the collar part 16 a″ is frusto-conical the slot 62 is preferably inclined at the same angle as the inner surface of the collar part 16 a″, resulting in the two slots 62 on each collar part 16 a″ being slightly inclined toward each other (FIGS. 20c, 20e ), and slightly further inclined toward the longitudinal axis 18 during use. The slot 62 may be slightly wider at the open top end of the slot, so the sides forming the slot 62 are further apart at the top opening of the slot and closer together at the closed bottom end of the slot 62. The distal edges 61 c of flange 60 are preferably inclined at the same angle as the taper of the collar part 16 a″ and slot 62.
Each collar part 16 a″ thus has a bottom portion 66 and a top portion 68 each with a frusto-conical inner surface and preferably a parallel frusto-conical exterior surface. An outwardly extending flange 60 extends outward from each diametrically opposing side of the base portion 66 along a juncture 69 between the flange 60 and the curved, preferably semi-circular body portion of the collar part. Closed ended slot 38 extends into the bottom portion 66 and opens onto the lower end of the collar part 16 a″. The slot 38 is preferably centered between the two flanges 60 and extends along axis 18 during use. The flanges 64 extend past the location of the longitudinal axis centerline 18 during use and thus the faces 61 b about 180° apart while the faces 61 a are more than 180° apart. The slot 62 extends from the top toward the bottom of the collar part 16 a″ to separate the top flange 64 from the upper portion 68. In particular the slot 62 aligns with the juncture 59 of the outwardly extending flange 76 and separates the flange 60 from the curved body portion of the collar par 16 a″ while the juncture 59 connects the bottom of the flange to the collar part.
The first collar portion 16 a″ with upward slots 62 is connected to a shelf 14 and orientated so the larger diameter of the conical shape of the collar portion 16 a″ is downward and the smaller diameter is at the top during use so as to mate with and wedge sleeve 20 against post 12 during use.
Referring to FIG. 20 (FIGS. 20a-20g ), the second collar portion 16 b″ has a frusto-conical body with a flange 50 extending outward from each side or distal edge of the collar part 16 b″. The frusto-conical body has a larger diameter lower edge and a smaller diameter upper edge so that when it interlocks with first collar portion 16 a″ the conical shape is larger at the lower end and smaller at the upper end. A flange 70 extends outward, preferably radially outward, from each side or distal edge of the collar part 16 b″. The flange 70 extends along a length of each side or distal edge of the collar part 16 b″, preferably along substantially the full axial length of the side or distal edge forming the juncture 69 with the curved and preferably semi-circular body portion of the collar part. Each flange 70 has two opposing sides or faces 71 a, 71 b and a distal edge 71 c. The side 71 a is on the same side of the collar part 16 b″ as the interior of the collar part and side 71 b is on the same side of the collar part 16 b″ as exterior side. In particular the slot 72 aligns with the juncture 69 of the outwardly extending flange 70 and separates the flange 74 from the curved body portion of the collar part 16 b′ while the attached portion of juncture 69 connects the flange 74 to the body part.
A closed-end slot 72 extends along a length of the normal juncture 69 of the flange 70 to the side of distal edge of the collar part 16 b″ to which the flange 70 is connected. In the depicted orientation the slot 72 extends downward. The slot 72 preferably extends about half the axial length of the collar part 16 b″, but may extend shorter or longer, preferably varying within about 15% of the length of the collar part 16 b″.
The slot 72 separates a portion of the flange 70 from the collar part 16 b″ to form a free end 74 on the flange 70, with the base of the flange 70 being connected to the collar part 16 b″. Because the second collar part 16 b″ is frusto-conical the slot 72 is preferably inclined at the same angle as the inner surface of the collar part 16 b″, resulting in the two slots 72 on each collar part 16 b″ being slightly inclined toward each other (FIGS. 21c, 21e ), and slightly further inclined toward the longitudinal axis 18 during use. The slot 72 may be slightly wider at the open end of the slot, so the sides forming the slot 72 are further apart at the opening of the slot and closer together at the closed end of the slot 72. The distal edges 71 c of flange 70 are preferably inclined at the same angle as the taper of the collar part 16 b″ and slot 72.
Each collar part 16 b″ thus has a bottom portion 78 and a top portion 76 each with a frusto-conical inner surface and preferably a parallel frusto-conical exterior surface. An outwardly extending flange 70 extends outward from each diametrically opposing side of the top portion 76 along juncture 69. Closed ended slot 38 extends into the top portion 76 and opens onto the top end of the collar part 16 b″. The slot 38 is preferably centered between the two flanges 70 and extends along axis 18 during use. The flanges 74 extend past the location of the longitudinal axis centerline 18 during use and thus the faces 71 a are about 180° apart while the faces 71 b are more than 180° apart. The slot 72 extends from the top 76 toward the bottom 78 of the collar part 16 b″ to separate the flange 74 from the bottom portion 78 while the remaining portion of juncture 69 connects the flange 74 to the body part.
The second collar portion 16 b″ is used to lock the sleeve parts 20 a, 20 b together and to interlock with the first collar portion 16 a″. The second collar portion 16 b″ may be used independently, or a different collar portion 16 b″ may be connected to each opposing end of end frame 44 to interlock a pair of first collar portions 16 a. The second collar part 16 b″ is orientated so the larger diameter of the conical shape of the collar portion 16 b″ is downward and the smaller diameter is at the top during use so as to mate with and wedge sleeve 20 against post 12 during use and to interlock with the first collar part 16 a″ to form a frusto-conical structure encircling a split sleeve 20 to clamp it against the post 12 during use.
Referring primarily to FIGS. 24a-24c but also to FIGS. 22-23, in use a sleeve 20 is positioned on a post 12. The first collar part 16 a″ connected to a shelf 14 is positioned above the sleeve 20 and moved along the post 12 and axis 18 so the slot 38 fits over support tabs 30 and inside the retaining flange 32 to hold the sleeve parts 20 a, 20 b together and to support the collar part on the sleeve. The second collar part 16 b″ is positioned above the first collar part 16 a″ and moved downward so the slots 62, 72 pass through each other and over the junctures 69, 59 of the other part and interlock the flanges 60, 70. The juncture 59 of the base portion 66 and a different flange 60 fits into each of the slots 72 and the juncture 69 of the top portion 76 and a different flange 70 fits into each of the slots 62. Each flange 70 abuts a different flange 60, with a free end 74 facing and preferably abutting against the portion of flange 60 joined to base portion 66, and with free end 64 facing and preferably abutting against the portion of flange 70 joined to top portion 76.
The free ends 64, 74 are cantilevered from the respective collar parts 16 a″ and 16 b″ and when the slots 62, 72 are interlocked by relative movement along axis 18, the free ends engage the flange on the other collar part to prevent lateral separation of the collar parts. Depending on the length of the slots 62, 72 and flanges 60, 70 different engagement lengths can be achieved. Preferably the slots 62, 72 extend about half the length of flanges 60, 70 and the slots are wide enough to allow insertion of the mating collar part into the respective slots in each collar part. Thus, the juncture of base portion 66 and flange 60 fits into slot 72 and slot 72 is configured to snugly receive the juncture of base portion 66 and flange 60. Likewise, the juncture of top portion 7 and flange 70 fits into slot 62 and slot 62 is configured to receive the juncture of top portion 76 and flange 70. The flanges 60 extend upward and slots 62 open upward, with flanges 70 extending downward and slots 72 opening downward, so the junctures of the parts may interlock with the slots.
The joinder of collar part 16 a″ to shelf 14 cooperate with flanges 60, 70 to prevents rotation of the collar parts about axis 18 during use as flanges 60, 70 abut to restrain rotation about axis 18 during use as well as to prevent lateral movement during use. The flanges 60, 70 and flange 50 and channel 52 abut each other and when connected to sleeve 20 and post 18, restrain rotation in the plane orthogonal to the axis 18 during use, and provide means for restraining rotation about an axis in the plane orthogonal to the axis 18 during use. The interlocking of first and second collar parts 16 a, 16 b by the flanges 15 mating with the U-shaped channel 52, and the interlocking of the collar parts by flanges 60 and 70 and interlocking slots 62, 72, provide interlocking collar means for interlocking the collar parts and preventing lateral separation of those interlocked collar parts, in a plane transverse to axis 18 of post 12 during use.
Referring to the FIGS. 18-19 and 23-24, the first interlocking connectors 16 a′, 16 a″ may be connected to a shelf 14, preferably with one interlocking connector at each corner. Each first interlocking connector may be positioned above a separate sleeve 20 on a separate post 12 and moved downward to so the slot 38 in each interlocking connector part engages the sleeve 20 and support tabs 30 on each sleeve. A second interlocking connector part 16 b, 16 b″ may be positioned above the shelf and moved downward along the post 12 so the slot 38 in each second interlocking connector part engages the tabs 30 on each sleeve to hold the sleeves together, to support the second connector, and to interlock the connector parts by engaging the flange 50 with channel 52 on mating collar parts, or by interlocking slots 62, 72 on the mating collar parts. Each second interlocking connector part may be separately connected (FIGS. 17a, 23a ) or a locking bar 44 that may have an interlocking connector part on each opposing end so as to interlock two mating first connector parts at the same time as in FIGS. 18, 23. Referring to FIGS. 18, 23, the second interlocking connector 16 b′, 16 b″ may be on a shelf 14, preferably at a corner. The interlocking connector on the shelf 14 may be the male or female connector (FIGS. 18, 19) and the mating connector the female or male connector.
A simplified shelving unit would include four corner posts 12, at least one and preferably more shelves 14 with interlocking collar parts 16 of any type as described herein at each location on the shelf (generally corners) where the shelf is to connect to the post 12. For a rectangular shelf 14 with four interlocking collar parts 16 a′, 16 b′, 16 a″, 16 b″, one at each corner to connect to four posts, two end frames 44 would be needed for each shelf with an appropriate interlocking collar part on each opposing end of the each end frame 44, or four single collar parts for each shelf—selected to mate with the collar part connected to the shelf. A shelving kit may be provided that preferably includes those parts and more preferably includes two, three, four, five or six shelves 14 with corresponding numbers of interlocking collar parts 16 a′, 16 b′, 16 a″, 16 b″ on each shelf, and twice the number of end frame connectors 44 as there are shelves (or four times the number of single collar parts and four times the number of sleeves 20 as there are rectangular shelves, or various combinations of end frame connectors 44 and separate collar parts as needed to interlock with each interlocking collar part on each shelf.
A kit may include the above combination of parts and combinations thereof. Thus, a simple shelving kit may have two shelves 14, which if rectangular in shape have an interlocking collar part 16 a, 16 a′, 16 a″ of any type described herein at each corner of the shelf. The kit would further include eight sleeves 20 and eight interlocking collar parts 16 b, 16 b′, 16 b″ of any type described herein that are either separated, or with pairs of collar parts 16 b′ or 16 b″ joined to form end frames 44. Each additional rectangular shelf added to the kit would preferably include four interlocking collar parts 16 a′, 16 a″, four interlocking collar parts 16 b′, 16 b″ and four sleeves 20. If two shelving units are joined horizontally together by having two shelves 14 with two collar parts 16 a′ or 16 a″ at one end fastening to the same two posts 12, then the number of end frames 44 may be reduced by half, as may the number of single piece collars that completely encircle the post, if such single piece collars are used instead of end frames 44 or individual collar parts 16 b′ or 16 b″.
If two shelving units are joined horizontally together then the end of the shelf sharing posts 12 in common with another shelf preferably has collar parts configured to interlock. Thus, one shelf may have four first interconnecting collar parts 16 a′ or 16 a″ of the same type and orientation, and the second shelf may have two first interconnecting collar parts 16 a′, 16 a″ and orientation as the first shelf, and two second interconnecting collar parts 16 b′, 16 b″ orientated to mate the first interconnecting collar 16 a′, 16 a″ on the first shelf. The collar parts on the shelves 14 that connect to the common or middle post must be configured to interlock with the collar parts on the other shelf. Thus, both shelves may have opposing ends of each shelf 14 with different collar parts such as 16 a′, 16 a″ on a first end and mating collar parts 16 b′, 16 b″ on the other end of the shelf. Alternatively, one shelf 14 may have all corners with the same collar part (e.g., 16 a′ or 16 b′, 16 a″ or 16 a″) and the other shelf may have all the opposing collar parts (e.g., 16 b′ or 16 b′, 16 b″ or 16 b″) with the collar parts oriented to mate at the common middle pole.
The collar parts 16 a, 16 b, 16 a′, 16 b, 16 a″ and 16 b″ are preferably made of sheet metal that is of substantially uniform thickness and then cut and bent to the desired shape and typically connected to metal shelves 14 by molten metal joining techniques such welding, soldering, brazing etc. The collar parts could be made of suitably strong molded plastics and connected to shelves 14 by adhesives or suitable mechanical connections, or the parts could be integrally molded with plastic shelves, formed at the same time and as a unitary part with the plastic shelves.
The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention. Further, the various features of this invention can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein.

Claims

What is claimed is:

1. An interlocking collar for use with a sleeve having a frusto-conical outer surface encircling a post having an outer surface with grooves at intervals along a length of the post, with a rib on the sleeve mating with one of the grooves, the collar part configured to wedge the sleeve against the post during use in order to position the sleeve and collar part along a length of the post, the interlocking collar comprising:

an annular collar having first and second separable and interlocking collar parts defining a frusto-conical interior passage extending along a longitudinal axis when joined together, the passage sized to engage the outer surface of the sleeve during use, each collar part extending about half way around the longitudinal axis, each collar part having a top and bottom with the bottom forming a larger diameter of the conical interior passage, with a closed ended slot extending through each collar part and extending along the longitudinal axis and opening onto the bottom of each collar part; and

interlocking means on each of the first and second collar parts for preventing lateral separation of those interlocked collar parts in a plane transverse to the longitudinal axis during use.

2. The interlocking collar of claim 1, wherein the interlocking means comprise a male flange having opposing sides and extending outward from each of two opposing sides of the first collar part and extending along a substantial length of each collar part measured along the longitudinal axis, each male flange having a thickness T between opposing sides of the flange and extending outward a distance between about 3T and 10T; and

a female channel extending outward from each of two opposing sides of the second collar part and extending along a substantial length of the second collar part measured along the longitudinal axis, each female channel having an open bottom configured to slidably receive one of the male flanges during use, each female channel extending along opposing sides of a different one of the male flanges during use.

3. The interlocking collar of claim 2, wherein each male flange has a trapezoidal shape.

4. The interlocking collar of claim 2, wherein the first collar part is connected to a shelf.

5. The interlocking collar of claim 2, wherein the male flange extends generally radially outward.

6. The interlocking collar of claim 2, wherein the second collar part is connected to a shelf.

7. The interlocking collar of claim 1, herein the interlocking means comprises a first collar part having a top end and bottom end with a distance H1 between the ends measured along the longitudinal axis, the bottom end forming a larger diameter portion of the frusto-conical passage, the first collar part having two first flanges each forming a first juncture with a curved portion of the first collar part as each first flange extends outward from diametrically opposing side of that curved portion of the first collar part, the first flanges extending a distance from the outside of the curved portion between about 3 and 10 times a thickness of the first flange, the first collar part having two, first closed ended slots extending through a thickness of the first collar along a length of the first juncture and opening onto the top end to define two first flanges each having a free upper end separated from an upper portion of the first collar part and each having a lower end joined to a lower portion of the first collar part along the first juncture during use, the first collar part having a third closed ended slot extending from the bottom end along the longitudinal axis and opening onto the bottom end, the third slot located at about the middle of the curved portion of the first collar part; and

a second collar part having a top end and bottom end with a distance H2 between the ends measured along the longitudinal axis, the top end forming a smaller diameter portion of the frusto-conical passage, the first collar part having two second flanges each forming a second juncture with a curved portion of the second collar part as each second flange extends outward from diametrically opposing side of that curved portion of the second collar part, the second flanges extending a distance from the outside of the curved portion between about 3 and 10 times a thickness of the second flange, the second collar part having two, second closed ended slots extending through a thickness of the second collar along a length of the second juncture and opening onto the top end to define two second flanges each having a free lower end separated from a lower portion of the second collar part and each having an upper end joined to an upper portion of the second collar part along the second juncture during use, the second collar part having a third closed ended slot extending from the bottom end along the longitudinal axis and opening onto the bottom end of the second collar part, the third slot located at about the middle of the curved portion of the second collar part;

wherein each first slot is sized to receive a different second juncture and each second slot is sized to receive a different first juncture when the first and second collar parts are engaged by relative movement along the longitudinal axis, and wherein each third slot is sized to engage a pair of different outwardly extending tabs on the sleeve during use.

8. The interlocking collar of claim 7 wherein the each first flange is generally parallel to a top portion of the second collar part and each second flange is generally parallel to a bottom portion of the first collar part when the first and second collar parts are engaged.

9. The interlocking collar of claim 7, wherein H1 and H2 are about the same.

10. The interlocking collar of claim 7, wherein the length of the first slots are about half of H1 and the length of the second slots are about half of H2.

11. The interlocking collar of claim 7, wherein the first and second collar parts have a substantially uniform thickness and the first and second flanges have a side inclined to the longitudinal axis and in a plane with that axis.

12. A kit for a shelving unit having at least two, generally horizontal shelves connected to at least three generally vertical posts, the kit comprising:

the at least three posts each having a longitudinal axis and a cylindrical cross-section along the portion of a length of the posts at which the shelves are to be connected, each post having a plurality of grooves therein at predetermined locations which grooves are orthogonal to the longitudinal axis;

at least six sleeves each having a cylindrical interior surface with at least one inwardly extending rib, the cylindrical surface configured to abut the post and encircle the longitudinal axis during use with the rib configured and located to fit in one of the grooves in the post during use, each sleeve having a frusto-conical exterior surface, each sleeve further having first and second support tabs extending radially outward from a bottom portion of opposing sides of each sleeve a short distance, each first and second support tab having an upwardly extending retaining flange extending along an exterior surface of the sleeve and offset therefrom by the support tab from which the retaining flange extends;

at least two shelves, each shelf having at least three first-collar parts located around a periphery of the shelf and facing outward from the shelf, each first-collar part having a frusto-conical interior surface smaller at the top and wider at the bottom and extending around an arc of about 180° along a first-collar part axis which coincides with the longitudinal axis during use, each first-collar part having a first slot therein extending parallel to the first-collar part axis, each first slot having a closed end and two opposing sides opening onto a bottom of the first-collar part in which the first slot is located, each first-collar part and its first slot sized so the first-collar part fits between one of the retaining flanges and exterior surface of the sleeve while the sides of the first slot fit on opposing sides of one of the first support tabs from which the retaining flange extends, with the first slot and first support tab configured so that the first slot fits snuggly over the first support tab;

at least six second-collar parts each having a frusto-conical interior surface that is smaller at the top and wider at the bottom and extending around an arc of about 180° along the first-collar part axis which coincides with the longitudinal axis during use, each second-collar part having a second slot therein with a closed end and two opposing sides opening onto a bottom of the second-collar part in which the second slot is located with the second slot extending parallel to the first-collar part axis during use, the first-collar part and second-collar parts interlocking to define a generally cylindrical interior passage, each second-collar part and its second slot sized so the second-collar part fits between one of the retaining flanges and exterior surface of the sleeve from which the retaining flange extends while the sides of the second slot fit on opposing sides of the second support tab from which the retaining flange extends, with the second slot and second support tab configured so that the second slot fits snuggly over the second support tab; and

13. The interlocking collar of claim 12, wherein the interlocking means comprise a male flange having opposing sides and extending outward from each of two opposing sides of the first collar part and extending along a substantial length of each collar part measured along the longitudinal axis, each male flange having a thickness T between opposing sides of the flange and extending outward a distance between about 3T and 10T; and

14. The interlocking collar of claim 12, wherein each male flange has a trapezoidal shape.

15. The interlocking collar of claim 12, wherein the first collar part is connected to a shelf.

16. The interlocking collar of claim 12, wherein the male flange extends generally radially outward.

17. The interlocking collar of claim 12, wherein the second collar part is connected to a shelf.

18. The interlocking collar of claim 12, herein the interlocking means comprises a first collar part having a top end and bottom end with a distance H1 between the ends measured along the longitudinal axis, the bottom end forming a larger diameter portion of the frusto-conical passage, the first collar part having two first flanges each forming a first juncture with a curved portion of the first collar part as each first flange extends outward from diametrically opposing side of that curved portion of the first collar part, the first flanges extending a distance from the outside of the curved portion between about 3 and 10 times a thickness of the first flange, the first collar part having two, first closed ended slots extending through a thickness of the first collar along a length of the first juncture and opening onto the top end to define two first flanges each having a free upper end separated from an upper portion of the first collar part and each having a lower end joined to a lower portion of the first collar part along the first juncture during use, the first collar part having a third closed ended slot extending from the bottom end along the longitudinal axis and opening onto the bottom end, the third slot located at about the middle of the curved portion of the first collar part; and

wherein each first slot is sized to receive a different second juncture and each second slot is sized to receive a different first juncture when the first and second collar parts are engaged by relative movement along the longitudinal axis, and wherein each third slot is sized to engage an different pair of outwardly extending tabs on the sleeve during use.

19. The interlocking collar of claim 18 wherein the each first flange is generally parallel to a top portion of the second collar part and each second flange is generally parallel to a bottom portion of the first collar part when the first and second collar parts are engaged.

20. The interlocking collar of claim 18, wherein H1 and H2 are about the same.

21. The interlocking collar of claim 18, wherein the length of the first slots are about half of H1 and the length of the second slots are about half of H2.

22. The interlocking collar of claim 18, wherein the first and second collar parts have a substantially uniform thickness and the first and second flanges have a side inclined to the longitudinal axis and in a plane with that axis.