Note: Descriptions are shown in the official language in which they were submitted.
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t
TITLE OF THE INVENTION
A Shelf Assembly for a Refrigerator Compartment
BACKGROUND OF THE INVENTION
(0001] Adjustable shelves are conventionally associated with
both the freezer compartment and the fresh food compartment of
conventional refrigerators. Such shelves or shelf assemblies are normally
constructed as cantilevered step-adjustable shelving or as a slidable shelf
which slides along channels or ledges in opposite side walls of the freezer
or fresh food compartment. Typical of such shelves and shelving, both
sliding and cantilevered, are disclosed in the following patents.
[0002] U.S. Patent No. 1,119,982 issued to Ohnstrand discloses
a glass slab 3 which sits upon "a filler 7 of suitable material, as cement"
(page 1, lines 52-53). A ledge 1 of an annular frame or "truss flange 2"
(page 1, line 40) supports the entire shelf. The glass slab 3 is basically
'dropped-in" from above.
[0003] In lieu of bonding a piece of glass to a frame, several
patents to Bienick (U.5. Patent Nos. 6,422,673 and 6,679,573) provide a
sliding shelf in which a piece of tempered glass is snapped-fit into a
substantially polygonal plastic frame. The latter is an innovation which
excludes the utilization of separately applied adhesive and does not
include complete rim encapsulation, as disclosed in U.S. Patent Nos.
5,362,145; 5,429,433 and 5,524,981, each of which are assigned to the
assignee of the present application. The latter three patents require
sophisticated molding techniques because a pair of metal shelf brackets
and a piece of tempered glass are held accurately during the closing of an
injection mold and thereafter polymeric/copolymeric material is injected
into the mold creating a rim or encapsulation which holds the shelf
brackets to the piece of tempered glass. Thus, glass-to-frame bonding,
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snap-fitting, encapsulation and the like are all quite commonplace
whether the shelving assembly is slidable or can be vertically adjusted
through the utilization of conventional refrigerator compartment
trackways.
[0004] U.S. Patent No. 4,886,236 in the name of Randall
discloses a shelf having a rim in which an edge of a piece of tempered
glass is inserted, followed by the insertion of a plurality of wedge
members which are driven or forced into a notch or groove which receives
the edge of glass to retain the latter components assembled.
[0005] Numerous other patents disclose frames made of a
single piece of plastic material, as in U.S. Patent No. 3,633,983 to
Whitcomb; individual frame members, as in U.S. Patent No. 4,923,260
granted to Poulsen; extruded rims, as in U.S. Patent No. 5,947,574 in the
name of Avendano; and multi-piece reinforced frames, as in U.S. Patent
No. 4,960,308 in the name of Donaghy.
[0006] The shelves of the latter patents and patents listed in
U.S. Patent No. 6,422,673 fairly reflect the scope and content of the prior
art as a whole in the field of shelving, particularly shelving or shelf
assemblies utilized in refrigerators, be they sliding shelves or vertically
step-adjustable shelves.
[0007] The particular shelf which is selected for a particular
refrigerator depends upon numerous factors, primarily among which is
price. Obviously, for so-called top-of-the-line refrigerators, more
expensive, durable, aesthetic, etc. shelving is generally utilized, and the
best shelving for the best and/or most expensive refrigerators is the
encapsulated shelving manufactured by the assignee of the present
application, and is reflected in such patents as U.S. Patent No. 5,524,981;
5,362,145; 5,429,433; etc. Such encapsulated shelving, whether sliding
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shelves or vertically adjustable shelves, are the so-called ~~Cadillac" of the
industry and are utilized in most of the more expensive refrigerators
found in the marketplace. As total wholesale/retail prices become more
competitive, particularly toward mid-line and lower cost refrigerators,
more expensive shelves, such as encapsulated shelves, can prove
competitively disadvantageous, irrespective of the quality of the products
and the aesthetics thereof. Because of the latter, the shelves of U.S.
Patent Nos. 6,422,673 and 6,679,573 were developed because they
provide excellent aesthetics at a lesser price without adversely effecting
functionality. However, the optimum shelf or shelf assembly would be a
combination of maximum functionality, highest aesthetics and lowest
price. In an effort toward achieving the latter, the present invention
provides each of the latter three objectives at as low a cost of
manufacture as is possible.
BRIEF SUMMARY OF THE INVENTION
[0008] A novel shelf assembly or shelf is constructed in
accordance with the present invention from but a single panel of
tempered glass and two plastic frame members in the case of a sliding
shelf and from a single piece of tempered glass, a single frame member,
and two support brackets in the case of a vertically step-adjustable shelf
or shelf assembly. In both cases, adhesive is not required and in lieu
thereof, the components of the shelves, whether sliding or vertically step-
adjustable, are provided with a plurality of inter-engageable stake
projections and stake projection openings. When appropriately
assembled, axial end portions of the stake projections are upset or staked
to form enlarged heads which unitize the shelf frames to the tempered
glass panel or a pair of shelf brackets, a single shelf frame and the
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tempered glass panel to each other in manufacturing sliding and vertically
step-adjustable shelving, respectively.
[0009] In further accordance with the present invention, both
in the case of a sliding shelf and a vertically step-adjusting shelf, two
polymeric/ copolymeric plastic frames are utilized and are stake-
assembled to each other to impart additional strength/reinforcement to
the shelf assemblies.
(0010] In accordance with the present invention, in the case of
a shelf assembly made of a single piece of tempered glass and two frame
members, one of the frame members is provided with stake projections
and the other frame member is provided with openings for receipt therein
of the stake projections. A peripheral edge of the tempered glass panel is
sandwiched between the two frame members and upon staking of the
axial ends of the stake projections, the three components of the shelf are
securely and rigidly assembled to each other absent the addition of
adhesive, bonding material, sealants or the like.
[0011] In the case of a vertically step-adjustable shelf,
preferably at least one of a pair of frame members includes depending
vertical flanges which carry stake projections which are inserted into and
through openings of shelf brackets and are thereafter staked or headed to
retain the shelf components in a rigid, unitized, aesthetic shelf assembly.
[0012] With the above and other objects in view that will
hereinafter appear, the nature of the invention will be more clearly
understood by reference to the following detailed description, the
appended claims and the several views illustrated in the accompanying
drawings.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIGURE 1 is front top perspective view of a novel shelf
or shelf assembly constructed in accordance with this invention, and
illustrates a pair of metal shelf brackets each having a pair of hooks, a
tempered glass panel, and two generally polygonal open frame members
collectively defining a rim bordering the glass panel of the shelf.
[0014) FIG~1RE 2 is an exploded fragmentary perspective view
of the underside of the shelf assembly of Figure 1, and from bottom to top
illustrates an upper/outer polygonal open frame member, the tempered
glass panel, a lower/inner polygonal open frame member and the pair of
shelf brackets prior to assembly of the components.
[0015] FIGURE 3 is a top perspective view of the shelf
assembly of Figure 2 partially assembled, and illustrates a peripheral edge
of the tempered glass panel sandwiched between the upper and lower
polygonal open frame members with stake projections of the upper
outermost open frame member being each received in a stake projection
opening of the lower innermost open frame member.
[0016] FIGURE 4 is a perspective view of the shelf assembly of
Figure 3, and illustrates stake projection openings of the metal shelf
brackets receiving stake projections of side frame portions of the upper
open frame member.
[0017] FIGURE 5 is a top perspective view of the shelf
assembly of Figure 4, and illustrates axial ends of the stake projections
being staked or enlarged to retain the components of the shelf assembly
in assembled relationship.
[0018] FIGURE 6 is an enlarged fragmentary cross-sectional
view taken generally along line 6-6 of Figure 4, and illustrates the
generally L-shaped transverse cross-sectional configuration of side frame
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portions of the inner and outer open frame members and the metal shelf
bracket; a locating member or tongue of the outer frame member snap-
secured in a locating opening of the inner open frame member; a stake
projection of the outer frame member projecting through a stake
projection opening of the shelf bracket, and a horizontal flange of the
shelf bracket engaged beneath a generally inverted L-shaped locating
portion or leg of the inner open frame member with the peripheral edge of
the tempered glass panel being sandwiched between horizontal flanges of
the inner and outer open frame member side portions.
[0019] FIGURE 7 is an enlarged fragmentary cross-sectional
view taken generally along line 7-7 of Figure 5, and illustrates the
identical components described with respect to Figure 6 and additionally
illustrating an axial terminal end portion of the stake projection being
staked into an enlarged staked head to retain the shelf components in
assembled relationship.
[0020] FIGURE 8 is an enlarged fragmentary cross-sectional
view taken generally along line 8-8 of Figure 5, and illustrates a plurality
of stake projections having enlarged stake heads disposed along a rear
frame portion of the shelf assembly with axes thereof substantially normal
to the axes of the stake projections of vertical flanges of the outer frame
member side portions.
[0021] FIGURE 9 is an exploded fragmentary perspective view
of another shelf assembly, specifically a sliding shelf, and illustrates a
pair
of generally polygonal open upper and lower frame members and a
polygonal tempered glass panel prior to being unitized, a plurality of
abutment bars for locating the tempered glass panel relative to the upper
open frame member, upwardly projecting stake projections of the latter,
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and stake projection openings of the lower open frame member
associated therewith.
[0022] FIGURE 10 is a perspective view of the sliding shelf or
sliding shelf assembly of Figure 9, and illustrates the components staked
together in assembled relationship.
[0023] FIGURE 11 is a fragmentary enlarged cross-sectional
view taken generally along line 11-11 of Figure 10, and illustrates the
manner in which a peripheral edge of the polygonal tempered glass panel
is sandwiched between horizontal flanges of the upper/outer and
lower/inner open frame members which are in turn held together by one
of a plurality of stake projections each received through a stake projection
opening and retained therein by an enlarged/staked head.
(0024] FIGURE 12 is a front fragmentary perspective view of a
refrigerator including one of a pair of side-by-side compartments thereof,
and illustrates the shelves of Figures 1 and 10 assembled respectively to a
pair of slotted vertical trackways and slidable upon opposite side wall
ledges.
[0025] FIGURE 13 is an enlarged cross-sectional view taken
generally along line 3-3 of Figure 12, and illustrates the manner in which a
lower surface of a vertical flange of a side frame portion of the outer open
frame member slides upon an upper surface of one of the refrigerator
compartment ledges.
(0026] FIGURE 14 is a bottom perspective view of another
step-adjustable shelf or shelf assembly constructed in accordance with this
invention, and illustrates an upper/outer generally polygonal open frame
member, a substantially polygonal tempered glass panel, and a pair of
metal shelf brackets which are collectively held in assembled relationship
by a plurality of stake projections of the open frame member housed in
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stake projection openings of the metal shelf brackets and having at axial
ends thereof enlarged staked heads.
[0027] FIGURE 15 is an enlarged fragmentary cross-sectional
view taken generally along line 15-15 of Figure 14, and illustrates the
components of Figure 14 in more detail, including one of the staked
projections projecting through the stake projection opening and an
enlarged staked head of the stake projection.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] A novel shelf or shelf assembly constructed in
accordance with this invention is illustrated in Figures 1 through 8 of the
drawings and is generally designated by the reference numeral 10. The
shelf or shelf assembly 10 is designed for vertical step-adjustment with
respect to a conventional pair of substantially vertically disposed slotted
tracks T1, T2 (Figure 12) in a freezer and/or fresh food compartment C of
a conventional refrigerator R which also includes opposite horizontally
aligned and vertically spaced pairs of ledges L1, L2 in respective side walls
S1, S2 of the compartment C for slidably accommodating another shelf 10'
of the invention which will be fully described hereinaftrer.
[0029] The shelf assembly 10 of Figures 1 through 8 and 12 is
defined by a pair of substantially polygonal open polymeric/copolymeric
synthetic plastic material frame members, including an upper, uppermost,
outer or outermost open frame member 11 and an inner, innermost, lower
or lowermost substantially polygonal open frame member 31. The shelf
assembly 10 further includes a substantially polygonal tempered glass
panel or piece of glass 50 and a pair of substantially identical metal shelf
brackets or shelf supporting brackets 70, 70.
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[0030] The outer open frame member 11 includes an inner
polygonal peripheral edge 12 defining a substantially polygonal opening
13; a pair of substantially parallel side frame member portions 14, 15; a
front frame member portion 16 having a forwardly and downwardly curved
finger gripping wall portion 19 and a rear frame member portion 17 which
is substantially parallel to the front frame member portion 16.
[0031] The side frame member portions 14, 15 each include a
horizontal flange 18 and, as viewed in Figure 1, a downwardly directed
vertical flange 20 with the horizontal flanges 18, 18 of the side frame
member portions 14, 15 being substantially in opposing relationship to
each other.
[0032] Each horizontal flange 18, 18 of the side frame member
portions 14, 15 carries means in the form of locating ribs or bars 21 which
are also provided along the flanges 18, 18 continuing along the front
frame member portion 16 and the rear frame member portion 17. The
locating ribs, bars or abutments 21 set-off a peripheral dimension which
corresponds substantially to a peripheral edge 51 of the tempered glass
panel 50. This enables the glass panel 50 to be ~~dropped-in" inserted into
the upper open frame member 11 from the position shown in Figure 2 to
the position evident from Figure 3 in which the glass panel 50 is accurately
located within and closes the opening 13 of the outer frame member 11.
[0033] The vertical flanges 20, 20 of the side frame member
portions 14, 15 each include four inwardly directed opposing
locating/latching tabs or tongues 22 which are each received in and are
snap-secured to an associated locating opening 32 (Figures 2, 6 and 7) in
a vertical flange 38 of the lower/inner open frame member 31. Inasmuch
as the tongues 22 are aligned with the openings 32 (Figure 2), the lower
open frame member 31 need but be moved downwardly from the position
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shown in Figure 2 into the upper/outer open frame member 11 and the
tongues 22 each snaps into one of the openings 32 during the outward
deflection and subsequent inward rebound of the vertical flanges 20 of the
side frame member portions 14, 15.
[0034] The outer open frame member 11 also includes four
stake projections 25 along the front frame member portion 16, the rear
frame member portion 17 and three stake projections 25 along each of the
vertical flanges 20 of the side frame member portions 14, 15. The stake
projections 25 of the side frame member portions 14, 15 are in axially
aligned opposing relationship to each other and axes (unnumbered)
thereof are substantially normal to the axes of the stake projections 25 of
the front and rear frame member portions 16, 17, respectively.
[0035] The inner/lower substantially open frame member 31
similarly includes an inner peripheral edge (unnumbered) corresponding in
size to the inner peripheral edge 12 of the outer frame member 11 and
defines a substantially polygonal opening 33. The inner open frame
member 31 includes substantially parallel spaced side frame members
portions 34, 35, a front frame member portion 36 and a rear frame
member portion 37 which are oriented for aligned assembly with the
respective frame member portions 14 through 17 of the outer open frame
member 11.
[0036] Each of the side frame member portions 34, 35 is of a
generally L-shaped transverse cross-sectional configuration (Figures 6
through 8) and is defined by the vertical depending flange 38 and a
horizontal flange 40 with the horizontal flanges 40 being disposed in
opposing aligned relationship. The horizontal flanges 40 carry four
substantially identical L-shaped locating and retaining legs, noses or feet
41 whose ends 42 (Figure 6) are spaced above the respective horizontal
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flanges 40 and define therewith a locating or retaining channel 43 for a
horizontal flange 73 each of the respective shelf brackets 70, as will be
more apparent hereinafter. Each of the vertical flanges 38 of the side
frame member portions 34, 35 includes four of the locating openings or
slots 32 heretofore described, and above three of the four locating
openings 32 in each flange 38 is an upwardly opening slot 45, as viewed in
Figure 2. The slots 45'. of the vertical flanges 38 of the side frame member
portions 34, 35 are aligned with each other and are each aligned with a
stake projection receiving opening or stake projection opening 71 in a
vertical flange 72 of each metal shelf bracket 70 which also includes the
horizontal flanges 73 disposed in aligned opposing relationship with each
other and a pair of hooks 75. The notches or slots 45 each receive or
accommodate one of the stake projections 25 projecting inwardly from the
vertical flanges 20 of the side frame member portions 14, 15, as is readily
apparent in Figure 3. In the partially assembled condition of the shelf 10
in Figure 3, the stake projections 25 of the front frame member portion 16
and the rear frame member portion 17 of the outer frame 11 project into
and through stake projections openings 39 of the respective front frame
member portion 36 and rear frame member portion 37 of the inner or
lower open frame member 31. The stake projections 25 of the side frame
member portions 14, 15 of the outer frame member 11 each project .
through one of the notches 45 in the vertical flanges 38 of the side frame
member portions 34, 35 of the lower frame member 31 and also pass
through the stake projection receiving openings 71 of the shelf brackets 20
(Figure 4), as will be immediately described hereinafter. Thus, fourteen
terminal axial ends (unnumbered) of the stake projections 25, of which
eleven are illustrated in Figure 3, are accessible for subsequent staking or
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enlarging under heat and pressure deformation, as will be described
hereinafter.
[0037] After the partial assembly of the shelf assembly 10
illustrated in Figure 3 is completed, each of the shelf brackets 70 is either
slid from left-to-right, as viewed in Figures 3 and 4, to insert each shelf
bracket 70 in the position shown in Figure 4 in which the stake projections
25 of the vertical flanges 20 of the side frame member portions 14, 15
project through the stake openings 71 of the shelf brackets 70 while each
horizontal flange 73 is engaged beneath an associated leg 42 (Figure 6)
and within the channel 43 formed thereby of each locating member 41.
[0038] In lieu of sliding the metal shelf bracket 70, 70 from left-
to-right in the manner just described with respect to Figure 3, the shelf
brackets 20 can be instead positioned substantially as shown in Figure 2 in
side-by-side relationship to the side frame member portions 14, 34; 15,
35 of Figure 3. The horizontal flanges 73 are then merely slid under the
legs or noses 41 of the locating members 41 which temporarily causes the
vertical flanges 20 to deflect outwardly but subsequently rebound to the
assembled position shown in Figures 4 and 6.
[0039] After the total assembly of the shelf or shelf assembly 10
of Figure 4, the exposed axial ends (unnumbered) of each of the fourteen
stake projections 25 are simultaneously staked in a conventional manner
under the application of heat and pressure resulting in the deformation of
the plastic material and the formation of enlarged heads or staked heads
60 which maintain and retain the components of the shelf 10 rigidly
assembled. The shelf or shelf assembly 10 can thereafter be utilized in the
compartment C (Figure 12) of the refrigerator R by hooking the hooks 75
of the shelf brackets 70 in any selected horizontally aligned pair of the
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slots (unnumbered) in the trackways T1, T2 to afford step-adjustment of
the shelf 10 in the compart C in a conventional manner.
[0040] The shelf or shelf assembly 10' earlier alluded to is
illustrated in Figures 9 through 11 of the drawings and has primed
reference numerals applied thereto to identify structure which corresponds
substantially identically to structure heretofore described with respect to
the shelf or shelf assembly 10. However, the major difference between
the two shelves I0, i0' resides in the fact that the shelf 10 includes the
two metal shelf brackets 70, 70 for achieving the step-adjustment
heretofore described, whereas the shelf 10' excludes such metal shelf
brackets and is formed as a sliding shelf defined by three components,
namely, a pair of substantially polygonal open polymeric/copolymeric
synthetic plastic material frame member, including an upper, uppermost,
outer or outermost open frame member 11' and an inner, innermost,
lower or lowermost substantially polygonal open frame member 31'. The
shelf assembly 10' further includes a substantially polygonal tempered
glass panel or piece of glass 50' having a peripheral polygonal edge 51'
[0041] The outer open frame member 11' includes sixteen
upwardly directed stake projections 25' having axes substantially in
parallel relationship to each other with each stake projection 25' being
aligned for inter-engagement into and with stake projection receiving
openings or stake projection openings 39' of the inner lower open frame
member 31' (Figure 9).
[0042] As in the case of the assembly of the shelf 10 described
with respect to Figures 2 through 4, the sliding shelf 10' is assembled in a
similar manner by the drop-in insertion or placement of the tempered
glass panel 50' into the upper open frame member 11' with the accurate
location thereof being assured by the locating ribs 21'. Thereafter, the
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lower open frame member 31' is moved downwardly from the position
shown in Figure 9 to the position shown in Figure 10 at which axial end
portions (unnumbered) of each of the upwardly directed stake projections
project into and through the stake projection openings 39' and with the
peripheral edge 51' of the tempered glass panel 50' being sandwiched
between the flanges 18', 40' of the respective open frame members 11',
31'. As is best illustrated in Figure 11, the vertical downwardly directed
flange 38' of the lower open frame member 31' extends about the entire
outer periphery of the lower open frame member 31' and bears against an
inner surface (unnumbered) of the horizontal flange 18' of the outer/upper
open frame member 11'. Thus, the peripheral vertical flange 38'
reinforces the entire periphery of the lower open frame member 31' to
prevent the same from distorting under the application of heat and
pressure when the axial end of each stake projection 25' is staked under
heated pressure to form the enlarged staked heads) 60' thereof (Figure
11). The sixteen staked projections 25' including the stake/enlarged
heads 60' thereof maintain the sliding shelf 10' in rigid assembled
relationship for its use in association with the ledges L1, L2 of the
refrigerator compartment C (Figure 12) in a conventional manner. It is to
be particularly noted from Figure 13 that each depending vertical flange
20' of the side frame member portions 14', 15' has a lowermost surface 65
which rides along the ledges L1, L2 and supports the shelf 10' in a manner
such that the enlarged staked heads 60' are spaced well above and do not
slide along upper surfaces (unnumbered) of the ledges L1, L2. This
prevents the enlarged staked heads 60' from being worn under the
influence of constant sliding friction during the use of the shelf 10',
particularly under the load of articles positioned thereupon. Because of
the absence of wear with respect to the enlarged staked heads 60', the
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longevity of the shelf 10' is enhanced and increased. It is also to be
particularly noted that from an aesthetic standpoint, none of the stake
projections 25, 25' or for that matter the locking members or tongues 22,
legs 41 or the openings 32 are visible from above when the shelves 10,
10' are in use (Figure 12). In other words, the uppermost/outermost
surface (unnumbered) of the uppermost open frame members 11, 11' are
essentially smooth, uninterrupted and offer no visible evidence of the
internally hidden components latter-described. Thus, when viewed in the
positions of use (Figure 12), the shelves 10, 10' give the appearance of an
expensive high-end encapsulated shelf absent the relatively higher cost
thereof while retaining the excellent functionability and high aesthetics of
encapsulated shelving.
[0043] Another vertically step-adjustable shelf or shelving
assembly 10"' is illustrated in Figures 14 and 15 of the drawings and
corresponds in all material aspects but one to the shelf 10, namely, the
shelf 10"' excludes the corresponding open inner lower frame member 31
while including the upper outer open frame member 11"', a piece of
thermal glass or glass panel 50"', and a pair of metal shelf brackets 70"'
each having a vertical flange 72' with a plurality of stake projection
openings 71"' therein, a pair of hooks 75"' and a horizontal flange 73"'.
As is most evident from Figure 15, the peripheral edge 51"' of the
tempered glass panel 50"' is accurately located and sandwiched between
the flanges 18"' of the inner open frame member 11"' and the flange 73"'
of each of the metal shelf brackets 70"'. The stake projections 25"' of
each of the vertical flanges 20"' of the outer upper open frame member
11"' project through the stake projection openings 71"' and are provided
with enlarged staked heads 60"' under heat and pressure, as heretofore
described to assemble the components in a rigid assembly suitable for
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supporting products in the compartment C of the refrigerator R. However,
since there are no stake projections 25"' along the front or rear member
portions 16"', 17"', respectively, of the upper open frame member 11"' of
the shelf 10"', an appropriate bonding material or adhesive can be utilized
in these areas to glue or bond an upper surface (unnumbered) of the
tempered glass panel 50"' directly to the underside of the horizontal
flanges 18"' of the front and rear frame member portions 16"', 17"',
respectively.
(0044] Although a preferred embodiment of the invention has
been specifically illustrated and described herein, it is to be understood
that minor variations may be made in the apparatus without departing
from the spirit and scope of the invention, as defined by the appended
claims.
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