SUPPORT BEAM AND SHELVING SYSTEM USING SAME

Abstract

A support beam (1) and a shelving system are provided. The support beam (1) comprises: a first vertical member (11); a second vertical member (12), positioned with the first vertical member (11) in a shared vertical plane; a horizontal member (13) connected to the first vertical member (11); a connecting member (14) connected to the horizontal member (13) and to an upper end (121) of the second vertical member (12), the connecting member (14) having a diagonal orientation such that the connecting member (14) is inclined downwards towards the second vertical member (12);and an extension member (15) having a first end (151) and a second end (152) and which is connected to a lower end (122) of the second vertical member (12) at the second end, the extension member (15) having a first straight portion (153) extending from the first end, and an angle between an extension direction of the first straight portion (153) and that of the second vertical member (12) being between 0 and 145 degrees. Figure to be published with the abstract: Fig. 1A;

Description

Title of the invention: SUPPORT BEAM AND SHELVING SYSTEM USING THE SAME FIELD OF THE INVENTION

[0001] The present invention relates to a beam structure and a storage device. More particularly, the present invention relates to a support beam and a shelving system using the support beams for various shelving systems to increase the efficiency of load carrying and bulk transportation.

[0002] BACKGROUND OF THE INVENTION

[0003] Boltless or riveted shelving systems are commonly used to store a variety of items in a space-saving manner while decreasing clutter, and are a popular storage option for any warehouse, factory, home, or garage due to their versatility and industrial strength. Typical shelving systems, as exemplified in U.S. Patent No. 8,424,694, may include four vertical corner posts, any suitable number of horizontal support beams extending between pairs of posts, and corresponding shelves resting on and carried by the pairs of horizontal support beams. In addition, boltless shelving systems are designed to be easy to assemble (i.e., require minimal tools) and to allow for quick and easy adjustments and reconfiguration of the shelving systems.

[0004] However, many boltless shelving systems, including those of the prior art mentioned above, have too low a load-bearing capacity or require diagonal bracing on the sides of the shelving system, which limits the usable space of the shelving system and the accessibility of said stored items. There is therefore a need for an optimal beam for use in a shelving system with high load-bearing capacity and increased accessibility. Summary of the invention

[0005] The present invention aims to provide devices that allow various shelving system beams in order to increase the efficiency of load carrying and bulk transport. Embodiments of the present invention can be freely combined with each other if they are not mutually exclusive.

[0006] The present invention relates to a support beam for carrying a shelf assembly. It comprises: a first vertical element; a second vertical element, positioned with the first vertical element in a shared vertical plane; a horizontal element connected to the first vertical element; a connecting element connected to the element horizontal and at an upper end of the second vertical member, the connecting member having a diagonal orientation such that the connecting member is inclined downward toward the second vertical member; and an extension member having a first end and a second end and which is connected to a lower end of the second vertical member at the second end, the extension member having a first straight portion extending from the first end, and an angle between an extension direction of the first straight portion and that of the second vertical member being between 0 and 145 degrees.

[0007] Preferably, a material of the support beam may comprise a metal or a plastic material.

[0008] Preferably, the extension element may also comprise a second straight portion extending from the second end.

[0009] Preferably, the first straight portion and the second straight portion may be parallel.

[0010] Preferably, the extension element may further comprise a U-shaped section between the first straight portion and the second end.

[0011] Preferably, the extension element may further comprise at least one arcuate section between the first straight portion and the second end.

[0012] Preferably, the extension element may further comprise at least one point of curvature between the first straight portion and the second end.

[0013] Preferably, the extension element may further comprise a flat portion perpendicular to the second vertical element between the first end and the second end.

[0014] Preferably, the first vertical member and the second vertical member at two ends of the support beam may further comprise an opening, respectively, for riveting, notching or bolting.

[0015] Preferably, the horizontal member and the connecting member may be cut at two ends of the support beam at an angle that is not perpendicular to the support beam.

[0016] The present invention also relates to another support beam for carrying a shelf assembly. It comprises: a first vertical member; a second vertical member, positioned with the first vertical member in a shared vertical plane; a horizontal member connected to the first vertical member; a connecting member connected to the horizontal member and to an upper end of the second vertical member, the connecting member having a curved shape; and an extension member having a first end and a second end and which is connected to a lower end of the second vertical member at the second end, the extension member having a first straight portion extending from the first end, and an angle between a direction of extension of the first straight part and that of the second vertical element being between 0 and 145 degrees.

[0017] Preferably, a material of the support beam may comprise a metal or a plastic material.

[0018] Preferably, the curved shape of the connecting element may comprise at least one point of inflection.

[0019] Preferably, the extension element may further comprise a second straight portion extending from the second end.

[0020] Preferably, the first straight portion and the second straight portion may be parallel.

[0021] Preferably, the extension element may further comprise a U-shaped section between the first straight portion and the second end.

[0022] Preferably, the extension element may further comprise at least one arcuate section between the first straight portion and the second end.

[0023] Preferably, the extension element may comprise at least one point of curvature between the first straight portion and the second end.

[0024] Preferably, the extension element further comprises a flat portion perpendicular to the second vertical element between the first end and the second end.

[0025] Preferably, the first vertical member and the second vertical member at two ends of the support beam may further comprise an opening, respectively, for riveting, notching or bolting.

[0026] Preferably, the horizontal member and the connecting member may be cut at two ends of the support beam at an angle that is not perpendicular to the support beam.

[0027] The present invention relates to a shelving system. It comprises: a plurality of corner posts; a plurality of beams, each beam being configured to be adjustably coupled to a pair of corner posts and at least one of the beams being the aforementioned support beam; and at least one shelf configured to rest on at least two beams.

[0028] Preferably, the shelving system may further comprise at least one fixing beam fixed to two opposing support beams.

[0029] Without intending to limit the present invention, the support beams are technically advantageous over the prior art because they can support more weight for the same amount of material. In addition, the packaging volume of a shelving system for shipping and handling can be reduced by about 50-70%. In some embodiments, the amount of reduction can be about 15%. Brief description of the drawings

[0030] [Fig. 1 A] is a side view of a support beam according to a first embodiment of the present invention.

[0031] [Fig.lB] shows a rear perspective view of the first embodiment.

[0032] [Fig. IC] shows a front perspective view of the first embodiment.

[0033] [Fig. 1D] shows another front perspective view of the first embodiment with four openings drilled on the support beam.

[0034] [Fig. 1E] shows a rivet fixed in each of the openings to connect the support beam.

[0035] [Fig.2] is a side view of a support beam according to a second mode of embodiment of the present invention.

[0036] [Fig.3] is a side view of a support beam according to a third mode of embodiment of the present invention.

[0037] [Fig.4A] is a side view of a support beam according to a fourth embodiment of the present invention.

[0038] [Fig.4B] is a side view of the support beam of the fourth embodiment which has a flat bottom portion.

[0039] [Fig.5] is a side view of a support beam according to a fifth mode of embodiment of the present invention.

[0040] [Fig.6A] is a side view of a support beam according to a sixth embodiment of the present invention.

[0041] [Fig. 6B] is a side view of a variant of the support beam according to a sixth embodiment of the present invention.

[0042] [Fig.7] is a side view of a support beam according to a seventh mode of embodiment of the present invention.

[0043] [Fig.8] is a side view of a support beam according to an eighth mode of embodiment of the present invention.

[0044] [Fig.9] is a side view of a support beam according to a ninth mode of embodiment of the present invention.

[0045] [Fig. 10] shows a support beam with cutouts at two ends.

[0046] [Fig. 11] shows a perspective view of one embodiment of a system of shelves.

[0047] [Fig. 12] shows how a support beam is attached to a corner post.

[0048] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0049] The present invention will now be described more specifically with reference to the following embodiments.

[0050] Reference is made to Figures 1A-1C. [Fig.lA] is a side view of a support beam 1 according to a first embodiment of the present invention, [Fig.lB] shows a rear perspective view of the first embodiment, and [Fig.lC] shows a front perspective view of the first embodiment. The support beam 1 is a long, straight object and its extension direction is perpendicular to [Fig.lA]. In order to enlarge the local features, a part of the support beam 1 between two ends thereof is omitted and is not drawn. Dashed lines in Figures 1B and 1C indicate the boundaries of the omitted part. The elements of the support beam 1 mentioned below are defined in [Fig.lA]. It is understandable that any element is also a long, straight object and connected to another to form the support beam 1 integrally. In [Fig.lA], dotted lines are used to distinguish one element from another related element.

[0051] In this embodiment, the support beam 1 for carrying a shelf assembly comprises a first vertical member 11, a second vertical member 12, a horizontal member 13, a connecting member 14, and an extension member 15. The second vertical member 12 is not connected directly to the first vertical member 11. Instead, the second vertical member 12 is positioned with the first vertical member 11 in a shared vertical plane. Thus, the first vertical member 11 and the second vertical member 12 can contact a plane of a corner post of a shelf, such that the support beam 1 is capable of attaching to the corner post. For ease of explanation, the second vertical member 12 has an upper end 121 and a lower end 122.

[0052] The horizontal element 13 is connected to the first vertical element 11. The connecting element 14 is connected to the horizontal element 13 and to the upper end 121 of the second vertical element 12. In this embodiment, the connecting element 14 has a diagonal orientation, such that the connecting element 14 is inclined downwards towards the second vertical element 12. The angle θ between the horizontal element 13 and the connecting element 14 can be variable.

[0053] The extension member 15 has a first end 151 and a second end 152. The second end 152 of the extension member 15 is connected to the lower end 122 of the second upright member 12. The extension member 15 also has a first straight portion 153 extending from the first end 151. In the present embodiment, the extension member 15 is shaped like a hook by the first straight portion 153, which increases rigidity against bending and twisting when the support beam 1 is assembled into a shelving system. An extension direction of the first straight portion 153, shown by a dotted arrow, and an extension direction of the second upright member 12 shown by a solid arrow are parallel. The angle between the two directions is 0 degrees. According to the present invention, the angle can range from 0 to 145 degrees. Other embodiments will include different examples of the first straight portion 153 to show different angles. The lower portion of the support beam 1 is arc-shaped.

[0054] According to the present invention, the following situations may apply. The total length of the support beams from one end to the other may be 1 to 10 feet. The width of the beam may be 1 to 6 inches. The thickness of the support beams may be uniform throughout and may be 0.5 mm to 3.0 mm. Regarding the material, according to the present invention, in all embodiments in the description, it may be, but is not limited to, metal, plastic, or any other rigid material.

[0055] The support beam 1 may be attached to a corner post to form part of the shelving system by welding. This is not the only way, however. The support beam 1 may be further processed to be bolted, riveted or notched with the corner post, or in any other way. Reference is made to Figures 1D and 1E. [Fig.lD] shows another front perspective view of the support beam 1 in the first embodiment, with four openings drilled on the support beam 1, and [Fig.lE] shows a rivet fixed in each of the holes for connecting the support beam 1. Each of the first vertical member 11 and the second vertical member 12 at two ends of the support beam 1 has an opening 20, respectively, for riveting, notching or bolting. There are four openings 20 shown in [Fig.lD].Rivets 21 are fixed in the openings 20 in the first vertical member 11 and the second vertical member 12. The rivets 21 may be replaced by bolts to fix the support beam 1 to the corner post. The difference between the rivets 21 and the bolts is that the former are fixed in the support beam 1 while the latter are applied only when fixing. For a better understanding, please refer to [Fig. 12]. The rivets 21 located at one end of a support beam 200 may be fixed to the pear-shaped holes 110 on the same corner post 100 to reinforce the stability of the shelving system, by maintaining the vertical alignment of the support beam 200 with the corner post 100.Alternatively, these rivets 21 may be attached to the pear-shaped holes 110 on separate corner posts 100 to extend the length of a single corner post, allowing multiple shelving systems to be stacked on top of each other.

[0056] Reference is made to [Fig. 2]. This is a side view of a support beam 2 according to a second embodiment of the present invention. In this embodiment, most of the elements of the support beam 2 are the same as the corresponding elements of the support beam 1. In order to simplify the explanation, the same symbols refer to the same element in different drawings and embodiments. Unless certain features are changed in terms of design, the details of the elements mentioned will not be repeated. In the second embodiment, the extension direction of the first straight portion 153 represented by a dotted arrow and the extension direction of the second vertical element 12 represented by a solid arrow are no longer parallel. An angle between the two directions is greater than 0 degrees, for example 30 degrees. The extension element 15 may still take the form of a hook thanks to the first straight portion 153 in order to increase the rigidity against bending and twisting in use.

[0057] Reference is made to [Fig. 3]. This is a side view of a support beam 3 according to a third embodiment of the present invention. In this embodiment, the design of the extension member 15 is different from that of the extension member 15 in the previous two embodiments. The extension direction of the first straight portion 153 represented by a dotted arrow and the extension direction of the second vertical member 12 represented by a solid arrow are perpendicular to each other. The angle between the two directions is 90 degrees. The extension member 15 is formed into an L shape by the first straight portion 153 and can also contribute to increasing rigidity against bending and twisting. The first straight portion 153 is parallel to and shorter than the horizontal member 13. The first straight portion 153 of [Fig.3] is rotated more degrees (about 60 degrees) counterclockwise compared to [Fig.2]. In practice, the angle between the two directions can be even larger up to the upper limit of 145 degrees mentioned above.

[0058] Reference is made to [Fig. 4A]. This is a side view of a support beam 4 according to a fourth embodiment of the present invention. The extension member 15 of the support beam 4 further comprises a second straight portion 154 extending from the second end 152. The first straight portion 153 and the second straight portion 154 are parallel. This makes the hook shape deeper. Furthermore, the extension member 15 has a U-shaped section 155 between the first straight portion 153 and the second end 152. The corresponding portion of the U-shaped section 155 in the first embodiment takes the form of an arc. The U-shaped section 155 may have arcs of the same diameter at the corners. Alternatively, the corners may also be right-angled. Reference is made to [Fig. 4B]. This is a side view of a variant of the support beam 4 which has a flat bottom.In particular, the U-shaped section 155 becomes a flat part 155' with a straight segment. The flat part 155' is perpendicular to the . second vertical element 12 between the first straight part 153 and the second end 152.

[0059] Reference is made to [Fig. 5]. This is a side view of a support beam 5 according to a fifth embodiment of the present invention. The extension member 15 of the support beam 5 has a bending section 156 replacing the U-shaped section 155 in the previous embodiment. The extension member 15 has at least one bending point between the first straight portion 153 and the second end 152. In this embodiment, there are two bending points indicated by two arrows. This forms discontinuous planes in the appearance of the bending section 156.

[0060] Reference is made to [Fig. 6A]. This is a side view of a support beam 6 according to a sixth embodiment of the present invention. The extension member 15 of the support beam 6 has three arc sections 157 replacing the bend section 156 between the first straight portion 153 and the second end 152 in the previous embodiment. According to the present invention, the number of arc sections 157 is at least one. This could give a wavy appearance to the lower portion of the support beam 6. According to the present invention, the arc sections 157 may also be between the first straight portion 153 and the U-shaped section 155. Reference is made to [Fig. 6B]. This is a side view of a variant of the support beam 6. It makes the hook wavy.

[0061] Reference is made to [Fig. 7]. This is a side view of a support beam 7 according to a seventh embodiment of the present invention. The extension member 15 of the support beam 7 has an inclined straight section 158 that replaces the three arc sections 157 of the previous embodiment. The lower part of the support beam 7 is curved at an angle. The distance between the second vertical member 12 and the first straight part 153 in the embodiment may be shorter than that of the horizontal member 13. It should be emphasized that the acute angles illustrated in Figures 4B, 5 and 7 are not exclusively limited to pointed shapes; they may also include smoothly curved angles on the outside and / or inside, similar to the smooth angles of the extension member 15 illustrated in [Fig. 4A].Furthermore, the first end 151 of the extension member 15 is not limited to a flat rectangular shape; it may have a concave or convex surface or also have a slight inward and / or outward curvature, forming a tail-shaped portion.

[0062] Reference is made to [Fig. 8]. This is a side view of a support beam 8 according to an eighth embodiment of the present invention. This embodiment is similar to the first embodiment except for the design of the connecting member 14. In the present embodiment, the connecting member 14 is connected to the horizontal element 13 and at the upper end 121 of the second vertical element 12. The connecting element 14 has a curved shape. As shown in [Fig.8], the connecting element 14 can be further separated into a first segment 141 and a second segment 142, which have an inflection point marked by a star between them.

[0063] According to the present invention, the curved shape of the connecting element 14 may have more than one inflection point. Regarding the design with several inflection points, reference is made to [Fig. 9]. This is a side view of a support beam 9 according to a ninth embodiment of the present invention. This embodiment is another design of the connecting element 14. The connecting element 14 may be further separated into a first segment 141, a second segment 142, a third segment 143 and a fourth segment 144. There are therefore three inflection points in this embodiment. It should be noted that the variants of the extension element 15 may also apply to the eighth and ninth embodiments.

[0064] In order to facilitate the assembly of a shelf system using the above-mentioned support beams, additional treatments may be applied to both ends of the support beam. Reference is made to [Fig. 10]. It shows a support beam with cutouts at both ends. The horizontal member 13 and the connecting member 14 are cut at both ends of the support beam at an angle that is not perpendicular to the support beam. The first vertical member 11 and the second vertical member 12 are not affected. Therefore, the section plane formed is not the cross-section of the support beam. In other words, a normal direction of the section plane on each end is not parallel to an extension direction of the support beam. As shown in [Fig.10], both ends of the support beam are gradually cut inward at the horizontal member 13 and the connecting member 14. In addition, a part of the extension member 15 at both ends of the support beam is removed. Thus, the treatments clear the openings on the side of the support beam so that the rivet or bolt can be installed. This also prevents interference of the support beam at the corners during assembly.

[0065] Reference is made to [Fig. 11]. It shows a perspective view of one embodiment of a shelving system 10. The shelving system 10 comprises a number of corner posts 100, a number of beams 200 and at least one shelf 300. In this embodiment, four corner posts 100, sixteen beams 200 and four shelves 300 are used for illustration purposes. This forms a rectangular shelf with four layers. In practice, the number of each element is not limited by [Fig. 11]. A greater number of beams 200 and shelves 300 can form the shelving system 10 with more layers.

[0066] In some embodiments, a layer of the shelving system may include more than one shelf 300. For example, the layer may include at least two shelves 300. In this embodiment, each shelf may be shorter than the length of the beam. This allows for increased height on a lower layer. For example, if only one of the shorter shelves is used in a layer, then an area of ​​said layer will be open such that taller items can be placed in a lower layer and pass through said open area.

[0067] The corner posts 100 may be manufactured by bending a strip of hard metal, forming two long straight plates connected at right angles. In order to fix the beams 200, a number of pear-shaped holes 110 are formed on each corner post 100. The locations of the pear-shaped holes 110 on all the corner posts 100 must be identical. The length of the corner posts 100 is not limited.

[0068] According to the present invention, the type of beams is not limited. Conventional beams not described in the present invention may be used. However, at least one of the beams 200 must be the support beam mentioned above. The lengths of the beams 200 are not limited. In this embodiment, two types of beams 200 with different lengths are used. Each beam 200 is configured to be adjustably coupled to a pair of corner posts 100. [Fig. 12] shows how the support beam 200 is attached to the corner post 100. In this particular embodiment, all the beams are the support beams of a single type of the first embodiment. Two rivets 21 at one end of the beam 20 pass through two corresponding pear-shaped holes 110 of the corner post 100 and are then wedged therein. In [Fig.12], it is evident that the cutouts at the ends of the beams 200 prevent the beams 200 from interfering with each other at the corner, as indicated by a dotted circle. When the beams 200 are securely attached to the corner posts 100 and a basic structure of the shelving system 10 is formed, the shelf 300 may rest on at least two beams 200. According to the present invention, the shelf 300 must generally be carried by four beams 200 for maximum load.

[0069] In some cases, if the length of the beams 200 is too great, the rigidity of the beams 200 is not sufficient to resist the bending moment caused by the loading of the shelf 300. To solve this problem, as shown in [Fig. 11], the shelf system 10 may further comprise at least one fixing beam 400. The fixing beam 400 may be fixed to two opposing beams 200 on the same layer, preferably at the center of the beams 200. In this embodiment, four fixing beams 400 are used, one for every two long beams 200 of each layer.

[0070] Although the preferred embodiment of the present invention has been shown and described, it will be readily apparent to those skilled in the art that modifications may be made thereto without departing from the scope of the invention. In certain embodiments, the figures presented in this utility certificate application are drawn to scale, including angles, dimension ratios, etc. In certain embodiments, the figures are representative only. In certain embodiments, the descriptions of the invention described herein using the phrase "comprising" include embodiments that could be described as "consisting essentially of" or "consisting of."

[0071] Although the invention has been described in terms of what are presently considered the most practical and preferred embodiments, it is understood that the invention need not be limited to the disclosed embodiments. Rather, it is intended to cover various modifications and similar arrangements within the scope of the invention, which should be given the broadest interpretation to encompass all such modifications and similar structures.

Claims

Claims

1. A support beam (1) for carrying a shelf assembly, characterized by comprising: a first vertical member (11); a second vertical member (12), positioned with the first vertical member (11) in a shared vertical plane; a horizontal member (13) connected to the first vertical member (11); a connecting member (14) connected to the horizontal member (13) and to an upper end (121) of the second vertical member (12), the connecting member (14) having one of a diagonal orientation such that the connecting member (14) is inclined downward toward the second vertical member (12) and a curved shape;and an extension member (15) having a first end (151) and a second end (152) and which is connected to a lower end (122) of the second vertical member (12) at the second end, the extension member (15) having a first straight portion (153) extending from the first end (151), and an angle between an extension direction of the first straight portion (153) and that of the second vertical member (12) being between 0 and 145 degrees.;

2. Support beam (1) according to claim 1, characterized in that a material of the support beam (1) comprises a metal or a plastic material.

3. Support beam (1) according to claim 1, characterized in that the extension element (15) further comprises a second straight portion (154) extending from the second end (152).

4. Support beam (1) according to claim 3, characterized in that the first straight part (153) and the second straight part (154) are parallel.

5. Support beam (1) according to claim 1, characterized in that the extension element (15) further comprises a U-shaped section (155) between the first straight part (153) and the second end (152).

6. Support beam (1) according to claim 1, characterized in that the extension element (15) further comprises at least one arc section (157) between the first straight part (153) and the second end (152).

7. Support beam (1) according to claim 1, characterized in that the extension element (15) further comprises at least one point of curvature between the first straight part (153) and the second end (152).

8. Support beam (1) according to claim 1, characterized in that the extension element (15) further comprises a flat portion (155') perpendicular to the second vertical element (12) between the first straight portion (153) and the second end (152).

9. Support beam (1) according to claim 1, characterized in that each of the first vertical element (11) and the second vertical element (12) at two ends of the support beam (1) further comprises an opening (20), respectively, for riveting, notching or bolting.

10. Support beam (1) according to claim 1, characterized in that the horizontal element (13) and the connecting element (14) are cut at two ends of the support beam (1) at an angle which is not perpendicular to the support beam (1).

11. Support beam (1) according to claim 1, characterized in that the connecting element (14) has a curved shape and the curved shape of the connecting element (14) comprises at least one inflection point.

12. A shelving system (10), characterized in that it comprises: a plurality of corner posts (100); a plurality of beams (1), each beam (1) being configured to be adjustably coupled to a pair of corner posts (100) and at least one of the beams (1) being the support beam according to one of claims 1 to 11; and at least one shelf (300) configured to rest on at least two beams (1).

13. Shelving system (100) according to claim 12, characterized in that it comprises at least one fixing beam (400) fixed on two opposite support beams (1).

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