US20090090686A1 - Shelving connector - Google Patents

Abstract

A connector is provided for securing two members together. The connector includes an opening formed in one member and a tab extending from the other member. Either the opening or the tab is tapered for frictional engagement with the other when the members are joined.

Description

CROSS-REFERENCES
• This application claims the priority benefit of U.S. Patent Application Ser. No. 60/640,791, “Shelving Connector”, filed Dec. 30, 2004, which is expressly incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
• This invention relates to the assembly of metal parts and more particularly to apparatus facilitating assembly of parts such as in sheet metal shelving or cabinets. Other applications are contemplated.
BACKGROUND
• Metal shelving is usually packaged in component pieces which are assembled to form shelving. Discrete fasteners are typically used in this process, as well as a variety of tab/slot arrangements as is well known. The use of discrete fasteners can increase cost and are the source of aggravation where quantities are mishandled or the like.
• Known tab and slot configurations can lack permanency and rigidity, especially when the shelving units are handled or manipulated. For instance, “bayonet-type” tab and slot configurations are known in the art and typically include a male tab protruding through an oversized slot so that movement of the tab within the slot is possible. In some instances, the slot may be oriented in a substantially vertical direction, with the bottom surface of the tab resting against the bottom of the slot via gravity. However, since the vertical dimension of the slot may be oversized relative to the vertical height of the tab, the tab and the member attached to the tab may move upwardly in response to the application of sufficient force, which can cause the assembled structure to wobble or to be otherwise undesirable.
• It is thus desired to provide improved connecting structure which produces position and rigid interconnection between elements of a structure such as a metal shelving or cabinet.
SUMMARY
• To these ends, one aspect of the present invention is directed to a connector for securing two members together. The connector includes an opening or aperture formed in one member and a tab extending from the other member. At least one of the opening and the tab is tapered for frictional engagement with the other when the members are joined.
• In one illustrative embodiment, a generally rectangular portion of a tab integral with one member is frictionally and securely engaged within a trapezoid shaped opening formed in the other member when the two members are joined. However, other shapes of openings and tabs are considered to be within the scope of the present invention provided the tab is frictionally and securely engaged with the opening when the two members are joined.
• A second aspect of the present invention is directed to a method for securing two members together without the use of discrete fasteners. With the method of the present invention, a plurality of openings are formed in one member and a plurality of tabs are formed in the other member so they extend from the other member. The members are aligned so the openings and tabs are in register with one another and the tabs are inserted through aligned ones of the openings. One of the members is moved relative to the other thereby wedging the tabs into frictional engagement with the openings to securely join the members together.
• In one illustrative embodiment, trapezoid shaped openings are formed in one member with tabs being formed in the other member. The tabs include a substantially rectangular portion. Each male tab is inserted into the larger end of the female trapezoid shaped opening and then slid to the narrower end of the female trapezoid shaped opening “wedging” the substantially rectangular portion of the tab securely into the female part. The tab also makes contact with the flat surface adjacent the female part opening also gripping it to insure a tight fit.
• Assembly of the two components or members of a shelving unit wedges them together and the combination of the wedged components and the flat surface engagement provides a strong, rigid, secure interconnection between the components. Use of discrete fasteners for this joint is eliminated and the female and male elements can be provided by stamping in the forming of the components or members, reducing the cost.
• These and other advantages will be appreciated from the following written description and from the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a perspective view of a cross-brace or shelf support member of a shelving unit provided with a plurality of tapered female connecting elements according to one embodiment of the invention;
• FIG. 2 is a cross-sectional view taken generally along lines2-2 ofFIG. 1;
• FIG. 3 is a plan, or flat pattern view of the developed member ofFIG. 1;
• FIG. 4 is a perspective view of another shelving member, such as a support column, showing a plurality of the male tab connecting elements according to one embodiment of the invention;
• FIG. 5 is a developed view of the member ofFIG. 4;
• FIG. 6 is an enlarged view of the encircled area ofFIG. 5 showing the male tab connecting element ofFIGS. 4 and 5;
• FIG. 7 is a cross-sectional view taken along lines7-7 ofFIG. 4;
• FIG. 8 is a cross-sectional view taken along lines8-8 ofFIG. 4;
• FIG. 9 is a perspective view illustrating cooperation of members like those ofFIG. 1 with that ofFIG. 4;
• FIG. 10 is a cross-section showing members ofFIGS. 1,4 and9 in interconnected configuration;
• FIG. 11 is a perspective view illustrating members ofFIGS. 1 and 4 in interconnected configuration; and
• FIG. 12 is a perspective view similar toFIG. 11, illustrating another embodiment of the invention.
DETAILED DESCRIPTION
• FIG. 1 depicts a brace orcross member10 of a shelving unit40 (FIG. 11). Shelvingmember10 preferably has top andbottom flanges11,13 and aweb15 and generally comprises, for example only, a sheet metal formed cross-brace or shelf support for a shelving unit40 (FIG. 11). The top andbottom flanges11,13 are angled relative toweb15. In the embodiment illustrated inFIGS. 1-11,flanges11 and13 are formed at substantially the same angle, i.e., about 90°, relative toweb15 asflanges11 and13 are both substantially perpendicular relative toweb15. However,flanges11 and13 can be formed at different angles relative toweb15 within the scope of the present invention.
• In the illustrative embodiment shown inFIGS. 1-11,member10 is provided with a plurality of female connecting elements orcomponents12 comprising inwardly tapered apertures or openings, from bottom to top. Each opening has atop edge20,bottom edge21 and taperedsides18,19. The taper in one embodiment is slight, on the order of 0.010″ sobottom edge21 is about 0.010″ longer than thetop edge20. In one embodiment,top edge20 is 0.370″ long and bottom edge is 0.380″ long. Any suitable taper can be used.
• The lowerfemale openings12 may extend intolower flange13 as best shown inFIGS. 1 and 9. However, the lowerfemale openings12 may also be disposed entirely withinweb15.
• FIG. 12 illustrates ashelving unit140 according to an alternate embodiment of the present invention. Shelvingunit140 is the same asshelving unit40, except thatmember10 is replaced withmember110.Member110 does not include thebottom flange13 ofmember10 but can be otherwise the same asmember10. Theweb15 ofmember110 includes a bottom orlower edge112. A plurality of theopenings12 are formed inweb15, and the bottom openings12 (only one is shown inFIG. 12, with the other being obscured) open onto thebottom edge112 ofweb15. The utilization ofshelving unit40 havingmembers10 withlower flanges13, or the use ofshelving unit140 havingmembers110 without lower flanges, can be based on one or more of the following considerations: cost, strength and spacing.
• Another shelving member such as a formedcolumn14 is shown inFIGS. 4-12 and is included inshelving unit40 andshelving unit140. This member in one embodiment comprises a formed sheet metal angle provided with a plurality ofmale tabs16.Tabs16 are integrally formed of the same material as the remainder ofcolumn14, using any suitable stamping or other process. As shown inFIGS. 6-8, eachtab16 includes aproximal portion33 integral with an adjacent, substantiallyplanar portion17 ofcolumn14. Theproximal portion33 oftabs16 includes first andsecond bend portions35,36.Tabs16 further include an upwardly extendingportion24 integral withproximal portion33 and an outwardlybent portion26 integral withportion24.
• In the illustrative embodiment, the upwardly extendingportion24 has generallyparallel edges25,27 and a substantially rectangular shape, as best seen inFIG. 6. As also shown inFIG. 6, the outwardlybent portion26 oftab16 has inwardly taperedsides22,23 to facilitate the insertion oftabs16 intoapertures12.
• The width of thetab portion24 fromedge25 to edge27 is about equal to or slightly greater than a length29 ofedge20, that extends betweensides18 and19 (FIG. 3) ofaperture12.
• Theapertures12 andtabs16 are oriented in their respective components ormembers10,14 (or110,14) so they are in register when the members are joined. Themembers10,14 (or110,14) are joined by inserting thetabs16 intoapertures12, and the members moved relative to one another so thetabs16 move upwardly inapertures12. This wedges thetabs16 frictionally in the taperedapertures12, holding themembers10,14 (or110,14) rigidly together.
• Note also inFIG. 10 that rearflat surfaces28 ofportions24 oftabs16 engageweb15 ofmember10, thus holding themembers10 and14 together securely. The opposite side ofweb15 is held againstcolumn14 in each illustrated embodiment. This also applies totabs16 engagingweb15 ofmember110, thus holding themembers110 and14 together securely.
• In a relaxed, free state condition, the configuration ofbend portions35,36 causes a substantially flat,planar surface28 of the upwardly extendingportion24 oftab16 to be displaced from asurface30 of the substantiallyplanar portion17 ofcolumn14 by a distance32 (FIG. 8). Preferably, bendportions35 and36 are configured so thatdistance32 is less than a width34 (FIG. 10) of theweb15 ofmember10. Accordingly, whenmembers10 and14 or110 and14 are assembled, as subsequently discussed further, a clamping force is applied between a substantiallyplanar surface38 ofweb15 ofmember10 ormember110 and the substantiallyplanar surface28 ofportion24 oftab16. The magnitude of the clamping force can be varied by changing the configuration ofbends portions35,36 to changedistance32 as may be appreciated.
• The combination of the wedged tab and the flat surface engagement provides a strong, rigid, secure interconnection between themembers10,14 or110,14.
• Tab width and aperture taper can be selected to provide more gentle or more aggressive wedging action. Also, as discussed previously, tab bends can be selected so the joining process clamps one component against another, the “springiness” of the tabs holding or biasing the members together.
• Due to the absence of fasteners, no tools are required for the connection of unit members. Instead, only joining, juxtapositioning and manipulation of the unit members are needed to provide secure interconnection.
• In use, then,members10 or110 are assembled, for example, to frame members such ascolumn14 for either bracing or support if shelves or items are to be stored directly thereon. This interconnection is produced merely by juxtaposingelements10,14 or by juxtaposingelements110,14 and moving them relative to each other so thattabs16 are introduced intoopenings12. Further motion securely couples the elements together without the need for discrete fasteners.
• It will be appreciated that sheet metal members other than those illustrated herein can be so joined by the connectors and methodology of the present invention, and the openings and tabs of the connector of the present invention can be used in other materials and other configurations, such as cabinets, furniture, buildings, togs and the like. Additionally, although the illustratedtabs16 include a generallyrectangular portion24 wedged into a trapezoid shapedopening12, alternately, therectangular portion24 may be replaced with a portion having tapered sides for fitting in a rectangular opening, thus still attaining the frictionally wedging action. Also, the previously described wedging action may be accomplished with openings and tabs having other shapes that are considered to be within the scope of the present invention.
• While the foregoing description has set forth preferred embodiments of the present invention in particular detail, numerous modifications, substitutions and changes will be appreciated without departing from the true spirit and scope of the present invention and applicant intends to be bound only by the claims appended hereto.

Claims (5)

1-14. (canceled)

15. A shelving unit having a shelf support for use with a pair of upright support columns having shelf support connecting tabs extending therefrom, said shelf support comprising:

A horizontally-oriented beam member having an elongated web with upper and lower edges and at least a top flange extending at an angle to said web and from and along said upper edge;

a plurality of openings in said web for receiving tabs of said columns when said shelf member is connected respectively thereto, said openings extending in said web to and through said lower edge thereof so that said openings comprise a notch in said web extending inwardly into said web from said lower edge,

wherein at least one of said tabs and said plurality of openings are tapered; and

wherein said beam member includes a bottom flange extending at an angle to said web and from and along said lower edge thereof, to form a flange corner;

at least two of said openings in said web extending into said bottom flange from said web.

16. A shelving unit as inclaim 16 further including other openings in said elongated web and fully defined in said elongated web proximate to but not in said bottom flange for receiving respective ones of said tabs.

17. A shelving unit as inclaim 16 wherein said respective openings are aligned in said beam member, one above the other.

18. A shelving unit as inclaim 17 wherein a tab is disposed in each of said aligned respective openings.

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