Continuous Shelf Bracket Structure for Torsion-Resistant Mounting
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Solution Overview
Problem
Conventional storage shelving systems face challenges due to the narrow width of wall studs, requiring multiple brackets and fasteners, which increases assembly time and costs, and are prone to torsional stress and structural rigidity issues, limiting their weight-bearing capacity and continuous shelving capabilities.
Innovation Solution
The proposed adjustable continuous shelf mounting system features a wall standard with staggered slots and support brackets with upper and lower tongues that engage these slots, allowing a single wall stud to support multiple shelves, reducing the number of required brackets and fasteners, and providing enhanced structural rigidity through a torsion-resistant design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple wall standards and brackets are used to support shelves on narrow wall studs, then each shelf can be supported individually, but the assembly time and cost increase significantly
Solution Approach 1:
The patent combines multiple bracket functions into a single integrated bracket assembly that can support multiple shelves simultaneously. The bracket includes multiple arms or supports that extend at different angles to accommodate multiple shelf positions, eliminating the need for separate brackets for each shelf and reducing assembly time while maintaining support reliability.
Solution Approach 2:
The bracket design incorporates multi-functionality by enabling a single bracket to serve multiple shelf support positions. The bracket can be adjusted or configured to support shelves at various heights and angles from a single mounting point on the wall stud, making the system more efficient and reducing the total number of components needed.
2Device complexity
If a single plate design is used for shelf brackets, then the structure is simple, but the bracket is prone to torsional stress and failure under increased weight
Solution Approach 1:
The bracket is constructed using composite materials or a composite structure combining multiple materials with complementary properties. This may include combining rigid materials for structural support with more flexible materials for stress distribution, or using layered composite structures that provide both strength and torsional resistance while maintaining relative simplicity in the overall design.
Solution Approach 2:
The bracket is divided into multiple segments or components that work together to distribute and resist torsional stresses. Instead of a single monolithic plate, the bracket may include multiple arms, supports, or structural elements connected in a way that each segment contributes to the overall strength and stability, allowing the bracket to handle increased weight loads effectively.
3Reliability
If multiple fasteners are used to secure shelves to brackets, then the connection is secure, but the assembly and disassembly process becomes time-consuming
Solution Approach 1:
The fastening mechanism is merged into an integrated system where the bracket and shelf connection incorporates built-in fastening features. This may include snap-fit connections, interlocking structures, or integrated fasteners that are part of the bracket design itself, allowing for secure connections with fewer separate fastening operations and improving assembly efficiency.
Solution Approach 2:
The connection system incorporates self-service features such as self-aligning or self-securing mechanisms that reduce the need for multiple separate fastening steps. The bracket or shelf may have built-in features that automatically engage or secure connections during assembly, making the process faster and more efficient while maintaining reliable connections.
Data Source
AI summary
In some embodiments an adjustable continuous shelf mounting system may comprise a wall standard comprising a plurality of upper slots and a plurality of lower slots. A support bracket comprising: a first support wing coupled to a first upper tongue configured to engage an upper slot of a wall standard and a first lower tongue configured to engage a lower slot of a wall standard; a second support wing coupled to a second upper tongue configured to engage an upper slot of a wall standard and a second lower tongue configured to engage a lower slot of a wall standard; and a shelf lip receiving valley formed between the first support wing and the second support wing. A shelf comprising a load bearing surface and a perimeter lip. The perimeter lip of the shelf is configured to be received in the shelf lip receiving valley of the support bracket.