Note: Descriptions are shown in the official language in which they were submitted.
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WALL MOUNTED STORAGE SYSTEM AND
RELATED COMPONENTS AND METHODS
TECHNICAL FIELD
[0001] This application relates generally to wall mounted storage systems
such as
those utilized in closets, pantries and garages.
BACKGROUND
[0002] Modular storage systems such as modular shelf systems utilized in
closets
are well known. A number of commercially available systems utilize an
elongated
horizontal hang rail from which a plurality of vertical standards are hung.
However, such
systems require the use of tools to install and are particularly difficult for
one person to
install. Moreover, under some circumstances the vertical standards can shift
laterally
relative to, bow outwardly or pivot away from the wall surface.
[0003] It would be desirable to provide a storage system that can be
installed
without tools, can be installed by a single person and that provide a more
stable mounting
of the vertical standards.
SUMMARY
[0004] In one aspect, a storage system includes at least one hang bracket
mountable
on a wall, the hang bracket including a base and a support portion. A vertical
standard
includes a front side having a plurality of mount slots distributed vertically
therealong, and
a rear portion configured for engagement with the support portion. At least
one anchor
component is pivotably positioned at a front side of the base, the anchor
component
including a pivot end and a retainer end. The retainer end includes at least
one wall
penetrating retainer extending therefrom and having a wall penetrating extent
that extends
rearwardly of the base when in an install position.
[0005] In another aspect, a storage system includes a plurality of hang
brackets
mounted on a wall, the hang brackets mounted at substantially the same height
and laterally
spaced apart. A plurality of vertical standards are provided. Each vertical
standard
includes a front side having a plurality of mount slots, with each vertical
standard hung
from a respective one of the hang brackets, wherein each hang bracket supports
only one
vertical standard.
[0006] In another aspect, a storage system includes at least one hang
bracket
mounted on a wall. A vertical standard includes a front side having a
plurality of mount
slots distributed vertically therealong, the vertical standard hung from the
hang bracket.
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The hang bracket includes a base with a back side seated against the wall, a
support portion
projecting outward and upward from the base. A plurality of anchors are
pivotably located
at a front side of the base, each anchor component including a pivot end and a
retainer end.
The retainer end includes at least one wall penetrating retainer extending
therefrom and
passing through a respective opening in the base such that a curved wall
penetrating extent
of the retainer is engaged within the wall so as to secure the hang bracket to
the wall.
[0007] In another aspect, a hang bracket and vertical standard
combination
mountable on a wall includes a hang bracket including a base with a back side
for seating
against a wall, and a plurality of anchor components pivotably located at a
front side of the
base. Each anchor component includes a pivot end and a retainer end, where the
retainer
end includes at least one curved wall penetrating retainer extending therefrom
and having a
rearwardly extending wall penetrating extent. Each anchor component is
pivotable
between a forward position and an install position. In the forward position
the retainer end
is moved away from the front side of the base and the wall penetrating extent
is forward of
the back side of the base, and in the install position the retainer end is
located adjacent the
front side of the base and the wall penetrating retainer passes rearward of
the back side of
the base. A vertical standard is supported by the hang bracket.
[0008] In another aspect, a hang bracket assembly is provided for use in
hanging a
vertical standard of a storage system from a wall. The hang bracket assembly
includes a
hang bracket with a base having a plurality of spaced apart openings, a lower
support
portion projecting outward and upward from the base and an upper retention
portion
extending outward from the base. A front side of the base, the support portion
and the
retention portion together form a channel. A plurality of anchor components
are pivotably
located within the channel, each anchor component including a pivot end and a
retainer
end, where the retainer end includes at least one curved wall penetrating
retainer extending
therefrom, and each anchor component is pivotable between a forward position
and an
install position. In the forward position the retainer end is moved away from
the front side
of the base and the wall penetrating retainer is forward of a back side the
base, and in the
install position the retainer end is located adjacent the front side of the
base and the wall
penetrating retainer passes through a respective one of the openings in the
base and
rearward beyond the back side of the base.
[0009] In another aspect, a hang bracket assembly is provided for use in
hanging a
vertical standard of a storage system from a wall. The hang bracket assembly
includes a
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hang bracket comprising a base having a plurality of space apart openings and
a support
portion projecting outward and upward from the base. A plurality of anchor
components
are pivotably located on a front side of the base, each anchor component
including a pivot
end and a retainer end, where the retainer end including at least one curved
wall penetrating
retainer extending therefrom. Each anchor component is pivotable between a
forward
position and an install position. In the forward position the retainer end is
moved away
from the front side of the base and the wall penetrating retainer is forward
of a back side of
the base, and in the install position the retainer end is located adjacent the
front side of the
base and the wall penetrating retainer passes through a respective one of the
openings in
the base and rearward beyond the back side of the base.
[0010] In another aspect, a storage system includes at least one hang
bracket
mounted on a wall, the hang bracket including a lower support portion and an
upper
retention portion. A vertical standard includes a front side having a
plurality of mount slots
distributed vertically therealong, the vertical standard hung from the support
portion of the
hang bracket. A cap member is mounted over the hang bracket, a rear side of
the cap
member configured to cooperate with the top end of the vertical standard and
the retention
portion to prevent the vertical standard from moving upward off of the support
portion
while the cap member is in place.
[0011] In another aspect, a storage system includes at least one hang
bracket
mounted on a wall. A vertical standard includes a front side having a
plurality of mount
slots distributed vertically therealong, the vertical standard hung from the
hang bracket.
An intermediate anchor is installed along a lower half of the vertical
standard to secure the
vertical standard against lateral movement along the wall and outward movement
away
from the wall.
[0012] In another aspect, a template is provided for installing a wall
mounted
storage system that includes multiple hang brackets, vertical standards and
intermediate
anchors. The template includes a sheet material having a plurality hang
bracket positioning
slots or openings therein and a plurality of intermediate anchor positioning
slots or
openings therein, wherein the sheet material has a collapsed configuration for
package
insertion and an expanded configuration for system install. The sheet material
is
configured such that in the expanded configuration (i) the sheet material has
a first
dimension and a second dimension running perpendicular to the first dimension,
the first
dimension longer than the second dimension, a first edge of the sheet material
is
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substantially linear and runs substantially parallel with the first dimension,
and (ii) when
the sheet material is placed adjacent a wall with the first edge of the sheet
material
positioned on the ground, each intermediate anchor positioning slot or opening
is located at
a respective intermediate anchor install location on the wall, and (iii) when
the sheet
material is placed adjacent the wall with the first edge of the sheet material
facing upward
and with each intermediate anchor positioning slot or opening aligned over one
of the
intermediate anchor install locations, then each hang bracket positioning slot
or opening is
located at a respective hang bracket install location on the wall, which hang
bracket install
location is vertically aligned above one of the intermediate anchor install
locations.
[0013] In another aspect, a template is provided for installing a wall
mounted
storage system that includes multiple hang brackets, vertical standards and
intermediate
anchors. The template includes a sheet material having a plurality hang
bracket positioning
slots or openings therein and a plurality of intermediate anchor positioning
slots or
openings therein, wherein the sheet material has a collapsed configuration for
package
insertion and an expanded configuration for system install. The sheet material
is
configured such that in the expanded configuration: (i) the sheet material has
a first
dimension and a second dimension running perpendicular to the first dimension,
the first
dimension longer than the second dimension, first and second major sides, a
first edge of
the sheet material is substantially linear and runs substantially parallel
with the first
dimension, the first edge including multiple support slots or openings
therealong or
adjacent thereto, and (ii) when the sheet material is positioned with the
first major side
adjacent a wall and with the first edge of the sheet material positioned on
the ground, each
intermediate anchor positioning slot or opening is located at a respective
intermediate
anchor install location on the wall, and (iii) when the sheet material is
placed with the first
major side adjacent the wall, the first edge facing downward and each support
slot or
opening aligned over one of the intermediate anchor install locations, then
each hang
bracket positioning slot or opening is located at a respective hang bracket
install location
on the wall, which hang bracket install location is vertically aligned above
one of the
intermediate anchor install locations.
[0014] In another aspect, a method of installing a wall mounted storage
system
including shelves involves: utilizing a template of sheet material that
includes a plurality of
openings spaced and positioned for defining storage system component locations
on a wall;
positioning the template adjacent the wall and installing storage system
components at
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positions defined by the template; removing the template from the wall;
installing
additional storage system components including at least first and second shelf
units;
breaking down the template into at least a first shelf liner and a second
shelf liner;
positioning the first shelf liner on the first shelf unit and positioning the
second shelf liner
on the second shelf unit.
[0015] The details of one or more embodiments are set forth in the
accompanying
drawings and the description below. Other features, objects, and advantages
will be
apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figs. 1 and 2 show an exemplary wall mounted storage system;
[0017] Figs. 3-13 show an exemplary hang bracket and standard
arrangement;
[0018] Fig. 14 shows another embodiment of a hang bracket and standard
arrangement;
[0019] Figs. 15-16 shows another embodiment of a hang bracket and
standard
arrangement;
[0020] Fig. 17 shows another embodiment of a hang bracket and standard
arrangement;
[0021] Fig. 18 shows another embodiment of a hang bracket and standard
arrangement;
[0022] Fig. 19 shows another embodiment of a hang bracket;
[0023] Fig. 20 shows another embodiment of a hang bracket;
[0024] Figs. 21-23 show one embodiment of an intermediate anchor and
standard
arrangement;
[0025] Figs. 24-25 show another embodiment of an intermediate anchor and
standard arrangement;
[0026] Figs. 26-27 show another embodiment of an intermediate anchor and
standard arrangement;
[0027] Figs. 28A-28D schematically depict various anchor assembly
arrangements
with retainers of differing angles of attack;
[0028] Figs. 29-30 show another embodiment of an intermediate anchor and
standard arrangement;
[0029] Figs. 31-33 show another embodiment of an intermediate anchor and
standard arrangement;
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[0030] Figs. 34-35 show another embodiment of an intermediate anchor and
standard arrangement;
[0031] Figs. 36-37 shows another embodiment of an intermediate anchor and
standard arrangement;
[0032] Figs. 38-39 show another embodiment of an intermediate anchor and
standard arrangement;
[0033] Figs. 40-41 show another embodiment of an intermediate anchor and
standard arrangement;
[0034] Figs. 42-46 show one embodiment of a template system; and
[0035] Fig. 47 shows another embodiment of a template system.
DETAILED DESCRIPTION
[0036] In the drawings and description of various anchor embodiments
below, the
term wallboard is generally used to refer to the most common wallboard such as
drywall,
but it is recognized that the anchor components could be suitable for any
other friable
wallboard material, such as dense corks or foams or other materials that can
crumble.
Accordingly, the term wallboard as used herein is intended to broadly
encompass, for
example, both typical drywall (aka plasterboard and gypsum board) and such
other friable
wallboard materials.
[0037] Referring to Figs. 1-13, a wall-mounted storage system 5 (e.g., in
the form
of a closet organization shelving system) utilizes a series of vertically
oriented and
horizontally spaced apart standards 10 mounted against the surface of a wall
8. Typically
such a storage system 5 will be adaptable to numerous configurations in terms
of number
of vertical standards 10, location of support brackets 202, and structure
fixed to the support
brackets. By way of example, Fig. 1 shows the storage system 5 with upper wire
rod-type
shelving 300 supported on four vertically aligned brackets 202 and lower wire
rod-type
shelving 302 supported on two vertically aligned brackets 202. On the other
hand, Fig. 2
shows the system 5 where the upper brackets 202 only support a rod-type hanger
304 (e.g.,
for hanging clothes on hangers). Many variations are possible.
[0038] Each vertical standard 10 includes a front side 12 having a
plurality of
mount slots 14 distributed vertically therealong. In the illustrated
embodiment, each
vertical standard is a channel or U-shaped member with left and right sides 16
and 18
extending rearward from the front side 12. The vertical standard may, for
example, be of
bent metal plate construction, but other variations are possible. In the
illustrated
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embodiment, pairs of side-by-side mount slots 14 are provided on the front
side of the
standard as shown, but other variations are possible.
[0039] The upper end of each vertical standard 10 is supported on the
wall 8 (e.g.,
of wallboard) by a manually installable hang bracket 20. The hang brackets are
mounted at
substantially the same height and in a laterally spaced apart manner along the
wall 8. In the
illustrated embodiment, each hang bracket 20 includes only one vertical
standard hung
therefrom, but other variations are possible.
[0040] In the illustrated embodiment, each hang bracket 20 is in the form
of a hang
bracket assembly 22 that includes a carrier bracket 24 and multiple anchor
components 28
(e.g., six in this case, though the number may vary). The carrier bracket 24
includes a base
26 with a front side 29 and a back side 30, where the back side 30 seats
against the surface
of the wall 8 for install. The base 26 also includes a plurality of laterally
spaced apart
through openings 38. A support portion 32 (e.g., in the form of a flange or
rail) of the
carrier bracket projects outward and upward from a lower end of the base 26,
and a
retaining portion 34 (e.g., in the form of a flange or rail) extends outward
from an upper
end of the base. The front side 29 of the base, the support portion 32 and the
retention
portion 34 together form a channel when viewed in end profile (per Fig. 5).
[0041] The anchor components 28, which may be of metal plate construction
(e.g.,
formed by progressive dies or cast), are pivotably located within the carrier
bracket channel
at the front side of the base 26. Each anchor component 28 includes a base
plate with a
lower pivot end 40 and an upper retainer end 42. The anchor components are
spaced
horizontally side-by-side along the base 26, with the pivot end 40 of each
anchor
component located behind the support portion 32. The retainer end 42 includes
a wall
penetrating retainer 44 extending therefrom and having a wall penetrating
extent that
protrudes rearwardly of the base plate and has a curved configuration. Each
anchor
component 28 is pivotable between a forward position (e.g., represented by
dashed-line
form 28' in Fig. 5) and an install position (e.g., per the solid line form of
the anchor
components in Figs. 3-5). In the forward position of an anchor component 28,
the retainer
end 42 of the anchor component base plate is moved away from the front side of
the carrier
bracket base 26 and the wall penetrating retainer 44 is forward of the back
side of the base
26. When the anchor components are all in the forward position the carrier
bracket 24 can
be moved around the wall 8 and/or pulled away from the wall 8. In the install
position of
an anchor component 28, the retainer end 42 is located adjacent the front side
of the base
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26 and the wall penetrating retainer 44 passes through a respective one of the
openings 38
in the base 26 and rearward beyond the back side of the base 26 and into the
wall 8 such
that the anchor components 28 thereby secure the hang bracket to the wall 8.
[0042] As shown schematically in Fig. 5, each wall penetrating retainer
44 includes
a primarily arcuate portion 45 (e.g., the wall penetrating extent of the
retainer 44) within
the wall 8. The radius of curvature (e.g., R45) defined by the wall
penetrating extent 45
has a center point that is proximate to the axial pivot point line or axis 50
of each anchor
component 28. This geometry minimizes the energy and force required to insert
each set of
retainers, minimizes damage to the wall and results in small wall surface
perforations when
the anchor component is removed. After the carrier bracket is positioned
adjacent the wall
8 in the desired install location, the anchor components 28 can each then each
be manually
pushed toward the wall 8 (e.g., one at a time by pressing with a thumb or
thumbs at the
retainer end), which rotates the corresponding wallboard piercing retainer 44
through the
hole 38 in the base 26 and into the wall 8.
[0043] Various configurations may be used to pivotably mount the anchor
components 28 to the carrier bracket 24 (e.g., such as portions of the carrier
bracket
including hinge rings that pass through slots in the pivot end of the anchor
component).
However, embodiments in which the anchor components are releasably retained in
the
carrier bracket 24 are also possible (e.g., the seat formed within the channel
between the
front side of the base 26 and the support portion 32 defines a anchor
component support
shelf and pivot line about which the lower edge of the pivot ends 40 of the
anchor
components 28 pivot for purpose of installation).
[0044] As noted above, each vertical standard 10 may be of U-shaped end
profile,
with the rear edge of each side wall 16 and 18 including a cutout or slot 52
to engage with
the support portion 32 so that the standard hangs from the support portion 32
as shown in
Figs. 6-8. The retention portion 34 of the carrier bracket includes laterally
spaced apart
slots 35 into which the side walls 16 and 18 fit for the purpose of such
mounting (e.g.,
when the standard 10 is in a raised position to align the lower edge of the
angled slots 52
with the free edge of the support portion. The angle on the slots may match
the angle on
the support portion as shown. One or more of the anchor components 28 may be
partially
or completely covered by the upper end of the vertical standard 10 when the
standard is
hung. A cap member 60 (e.g., of molded plastic) can be mounted over the hang
bracket 20
and upper end of the standard 10 to provide a clean appearance as shown in
Figs. 9-10.
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[0045] As shown in Figs. 11-13, the rear side of the cap member 60
includes a
recessed space 62 to size and shaped to surround the carrier bracket 24. The
recess 62 may
generally have a perimeter shape that matches a perimeter shape of the carrier
bracket.
Notably, the recessed space 62 may also include one or more features
configured to
cooperate with the top end of the vertical standard 10 and the retention
portion 34 of the
carrier bracket 24 to prevent the vertical standard 10 from moving upward off
of the
support portion 32 of the carrier bracket 24 while the cap member 60 is in
place.
[0046] In this regard, in the illustrated embodiment, the recess 62
includes an upper
lateral extent 64 that includes an upper edge 66 sized and configured to fit
snugly against
the top edge of the carrier bracket and lower edge 68 sized to fit below the
retention portion
34. A central pocket 70 receives the upper end of the vertical standard. A
retaining lip
portion 72 of the cap member is defined by material between lower edge 68 of
lateral
extent 64 and the upper edge 74 of the pocket 70. The retaining lip portion 72
is positioned
between the top end of the vertical standard and the bottom of the retention
portion 34.
Thus, retaining lip portion 72 interacts with the retention portion 34 to
prevent upward
movement of the vertical standard (e.g., if the vertical stand 10 moves
upward, the top edge
of the standard engages and is blocked by the retaining lip portion 72 of the
cap member).
The lower end of the recessed area is bound by lower lip portions 76 and 78
(separated by
the pocket 70) that are shaped to fit snugly against the bottom edge of the
carrier bracket.
The forward side of the cap member may be of any suitable or desired shape,
and may
include ornamental features to enhance the external appearance.
[0047] While a cap member is primarily described above, other
arrangements for
limiting vertically upward movement of the standard off of its hang bracket
are possible,
including other retaining components mounted to the hang bracket, or other
retaining
features integrated into the hang bracket.
[0048] It is recognized that a variety of different hang bracket
configurations are
possible, as suggested by the additional embodiments discussed below.
[0049] Fig. 14 depicts a hang bracket 20-14 similar to hang bracket 20
above
except that the carrier bracket 24-14 carries three anchor components 28-14,
where each
anchor component 28-14 includes two wall penetrating retainers 44-14 rather
than one. A
narrower version of the Fig. 14 embodiment could include just three vertically
spaced
anchor components.
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[0050] Figs. 15-16 depict a hang bracket 20-15 in which six anchor
components 28-
15 are utilized, each with a single wall penetrating retainer, where side by
side pairs of the
anchor components are spaced vertically along the height of the carrier
bracket base 26-15.
In this embodiment, the support portion 32-15 projects outward and upward from
an upper
end of the base 26-15, and no retention portion is used. In the Fig. 15
embodiment, each
side-by-side pair of anchor components could be replaced with one wide anchor
component
having two retainers (e.g., resulting in a three anchor component
arrangement).
[0051] Fig. 17 depicts a hang bracket 20-17 in which six anchor
components 28-17
(each with a single wall penetrating retainer) are used. Laterally spaced
apart pairs of the
anchor components (resulting in a gap between the anchor components that is
wide enough
to fit the vertical standard 10) are spaced vertically along the height of the
base 26-17, and
the support portion 32-17 extends from the lower end of the base.
[0052] While the above described hang bracket configurations all depict a
support
portion that generally extends the full lateral width of the hang bracket, it
is recognized that
support features other than flanges could be used. By way of example,
referring to Fig. 19,
an exemplary hang bracket 20-19 (anchor components not shown) includes a
support
portion 32-19 takes the form of spaced apart tabs 290, 292 (e.g., stamped from
the bracket
body) onto which a lateral internal pin at the upper end of the standard 10
could sit. Fig. 20
shows a hang bracket 20-20 with a support portion 32-20 that spans only a
portion of the
hang bracket width and includes lateral tabs 282 for lateral alignment of the
standard.
[0053] In some embodiments it may also be possible to effectively
integrate the
hang bracket with the vertical standard as suggested by the embodiment of Fig.
18 in which
the hang bracket 20-18 is formed by lateral flanges 80 and 82 that extend from
the sides 16
and 18 of the standard 10-18. A set of three anchor components 28-18 are
spaced
vertically along each flange 80, 82. Thus, each flange 80 and 82 forms the
hang bracket
base, and no support portion is needed due to the integral configuration of
the flanges with
the standard (e.g., the flanges may be formed unitary with the standard sides
and bent
outward, or may be formed separately and then welded thereto).
[0054] One common feature of all of the above-described hang bracket
embodiments is the relatively small size of the hang bracket. In particular,
because only a
single vertical standard hangs from each hang bracket, a longest dimension of
the hang
bracket may, in some implementations, be no more than about three inches.
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[0055] Referring again to Fig. 1, each vertical standard 10 hangs
downward from
its respective hang bracket along the wall, with the bottom end of the
standard spaced
above the floor. In order to provide additional stability to the standards 10
in an overall
system, one or more intermediate anchors may be provided for each of the
standards. A
primary purpose of the intermediate anchors is to secure the downwardly
hanging portion
of the standard against lateral movement along the wall and/or outward
movement away
from the wall. Accordingly, it is preferred that at least one intermediate
anchor be
provided along the lower two thirds (e.g., the bottom half) of each standard,
such as at
location 90 shown in Fig. 1.
[0056] Referring to Figs. 21-23, in one implementation, an anchor
assembly 100
may be used as the intermediate anchor. The anchor assembly 100 includes a
base member
112 including a wall facing side 114, outer side 116, lateral sides 118 and
120 and opposite
ends 122 and 124. Lateral sides 118 and 120 extend from the wall facing side
12 to the
outer side 116. The ends 122 and 124 are distal portions in a lengthwise
(longer) direction
or axis 126 of the base member.
[0057] The wall facing side 114 includes a base surface 128 for seating
against the
wall 8. In the illustrated example the base surface is a single planar
surface, but it is
recognized that variations are possible, such as the base surface being made
up of multiple
discreet surfaces that together lie in a common plane. The outer side 116 of
the base
member includes anchor support surfaces 132 and 134 that are angled relative
to each
other. In the illustrated embodiment the surfaces 132 and 134 converge toward
each other
as they move from respective ends 122 and 124 toward a mid-section 136 of the
base
member. Both anchor support surfaces 132, 134 are nonparallel with the base
surface 128,
with the outer end 138, 140 of each anchor support surface positioned closer
to the base
surface 128 than the inner end 142, 144 of the anchor support surface. Each
anchor support
surface 132 and 134 is substantially planar in this embodiment, with the two
surfaces
ramping toward each other. It is, however, recognized that variations with non-
planar
support surfaces are possible. It is contemplated that the base member 112 may
be formed
of a plastic or other polymeric material, but base members of metal or other
materials are
also possible.
[0058] Anchor components 150 and 152 are positioned on the base member
112.
Each anchor component 150, 152 has a respective pivot end 154, 156 and a
respective
retainer end 158, 160. Anchor component 150 is pivotable relative to the base
member 112
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between a forward position in which the retainer end 158 is spaced away from
the anchor
support surface 132 and an install position in which the retainer end 158 is
positioned
toward the anchor support surface 132. Likewise, anchor component 152 is
pivotable
relative to the base member 112 between a forward position in which the
retainer end 160
is spaced away from the anchor support surface 134 and an install position in
which the
retainer end 160 is positioned toward the anchor support surface 134. In the
install position
contemplated for each illustrated anchor component, a back side of the anchor
component
seats against its adjacent anchor support surface.
[0059] The retainer end 158 includes one or more wall penetrating
retainers 162
with wall penetrating extents that extend rearwardly such that when the anchor
component
150 is in the forward position the curved wall penetrating retainer extends
toward but not
beyond the base surface 128 and when the anchor component is in the install
position the
curved wall penetrating retainer 162 extends beyond the base surface to enable
wall
penetration. Likewise, the retainer end 160 includes one or more similar
curved wall
penetrating retainers 166. While each anchor component is shown with two
retainers, more
than two retainers could be provided, as could a single retainer.
[0060] The wall penetrating extents of the retainers 162 and 166 have a
primarily
curved configuration (e.g., of an arcuate configuration similar to that
described above),
where the radius of curvature defined by the arcuate portions of the wall
penetrating
retainers have a center point that is proximate to the axial pivot point line
or axis of each
anchor component 150, 152. In this regard, in the illustrated embodiment each
anchor
component 150 and 152 is independently associated with the base member 112 and
mounted thereto by respective pin and slot arrangements 167 and 169. The
central portion
136 of the base member includes a pivot base 170 having a laterally extending
slot 172,
174 on each side for receiving the pivot end of the respective anchor
component 150, 152
and the slots interact with the anchor component pivot ends to define the
pivot axis for each
anchor component. The radius of curvature of the anchor component retainers
may be
substantially centered in the respective slot 172 or 174. This geometry
minimizes the
energy and force required to insert the retainer into the wall, and minimizes
damage to the
wall and results in small wall surface perforations when the anchor component
is removed.
Pins (not shown) may be included to retain the anchor components on the base.
[0061] As best seen in Figs. 22 and 23, the anchor assembly 100 may be
sized to fit
within the channel at the back side of the vertical standard 10. After the
anchor assembly
12
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110 is installed in the wall and the standard located over the anchor
assembly, the standard
may be engaged with the anchor assembly in any suitable manner. In Fig. 23,
one or both
sides of the standard may include one or more slots 180 through which one or
more pin(s)
182 pass to make the connection. The slots may be elongate in the vertical
direction and
located such that the vertical weight of the standard, as well as any shelving
and storage
load carried by the standard, is not supported vertically by the intermediate
anchor
assembly 100. The base member 112 may include one or more lateral openings to
receive
the pin. The interaction between the pins 182 and the edges of the slot 180
will prevent the
standard from being pulled outward away from the wall. Moreover, interaction
between
the sides of the standard and the anchor assembly will prevent the standard
from moving
laterally relative to the wall. Where two vertically spaced apart pins are
used as shown, the
two pins inhibit rotation of the anchor assembly when forces are applied to
pull the
standard away from the wall.
[0062] It is recognized that a variety of different intermediate anchor
configurations
are possible, as suggested by the additional embodiments discussed below.
[0063] Figs. 24 and 25 show an embodiment in which the intermediate
anchor
assembly 100-1 includes a base member 112-1 is configured with slots 190 into
which
retention fingers 192 of the anchor components are positioned. Pins 182 and
slots are again
used for engagement between the anchor assembly 100-1 and the standard 10.
[0064] Figs. 26 and 27 show an embodiment in which the intermediate
anchor
assembly 100-2 includes base member 112-2 with an elongated mid-section 136-2
that
includes a set of side-by-side slots 198 that align with a corresponding set
of the slots 14 in
the front side of the standard 10. Rearwardly extending upper support fingers
200 of a
shelf bracket 202 can be inserted into the slots 198. The lower anchor
component 152-2 of
the assembly may align with rearwardly extending lower support fingers 204 of
the shelf
bracket 202, which fingers 204 may engage the lower anchor component such that
the shelf
bracket (and ay weight supported thereon) helps to maintain the anchor
component 152-2
and anchor assembly in place.
[0065] One common and beneficial feature of intermediate anchor assembly
embodiments 100, 100-1 and 100-2 is that the center of the radius of curvature
of the
anchor component retainers of both anchor components, also the pivot point of
both anchor
components, is offset from the wall surface and, in embodiments that include a
base
member, the base surface. This offset increases the angle of attack of the
retainer into the
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wall. The angle of attack of a given retainer can be defined as the angle
between a line or
plane running from the point of retainer entry into the wall to the pivot axis
about which
the retainer moves and a line or plane normal to the wall surface. Referring
to Figs. 28A-
28D, various anchor assembly configurations are shown with anchor components
in
installed positions within the wall. The anchor assemblies include respective
points of
retainer entry 800A-800D, respective retainers 802A-802D, respective pivot
axes 804A-
804D, respective normal lines 806A-806D and respective angles of attack aA-aD
for one
anchor component 808A-808D of the illustrated anchor assembly 810A-810D. It is
recognized that the other anchor component of each anchor assembly includes a
similarly
defined angle of attack.
[0066] As suggested by the schematic depictions, as the pivot point of an
anchor
component retainer moves outward away from the wall surface, the angle of
attack
increases and the amount of wall material encompassed by the retainer to
resist pull-out of
the retainer perpendicular to the wall surface (as represented by triangular
areas 812A-
812D) increases. Likewise, the anchor retention capability under cantilever
loads (such as
from a shelf supported on the anchor assembly) also increase. The most
critical feature
regard to these advantages is the increase in the linear extent to which the
curved retainer
lies behind the wallboard surface, as reflected in each case by line 814A-814D
(e.g.,
basically the linear projection of the retainer in the wall surface plane). In
the illustrated
case, retainer 802A is shorter than retainer 802B, which in turn is shorter
than retainer
802C, which in turn is shorter than retainer 802D, with all retainers
approaching, but not
passing through the backside of the wallboard, as is preferred. However, even
in the case
where the retainers 802B ¨ 802D were all the same length as retainer 802A, the
retainers
802B ¨ 802D would progressively encompass more wallboard material.
[0067] Generally, it has been discovered that although more wall material
can be
encompassed by the retainers using a more aggressive angle of retainer attack,
the force
required for anchor component insertion also increases. It has been determined
that a
desirable range for balancing these two characteristics is to provide an angle
of attack in
the range of between about fifty-five degrees and about eighty degrees, such
as about sixty
degrees to about seventy-five degrees. However, other variations in the angle
of attack are
contemplated.
[0068] Figs. 29 and 30 show an embodiment in which the intermediate
anchor
assembly 100-3 is located alongside the standard 10 and interconnects with the
standard via
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a pin 210 that protrudes from a side of the standard. The anchor assembly
includes a pin
sleeve 212 that defines a receiving channel for the pin 210. A back plate 214
of the anchor
assembly includes a wall penetrating retainer 216, which may have a primarily
arcuate wall
penetrating extent as described above, portion with a radius of curvature
centered on the
center of the sleeve channel or the lower edge of the back plate, which serves
as the pivot
point for wall installation. Although Figs. 29 and 30 depict only one anchor
assembly 200-
3 on the right side of the standard, a similar anchor assembly (mirror image
configuration)
could be provided on the left side as well.
[0069] Figs. 31-33 show an embodiment in which a pair of intermediate
anchors
100-4 engage with each side of standard 10. In particular, each side of the
standard
includes vertically spaced apart slots 220 into which mount flanges 222 with
vertically
extending fingers extend. The interaction between the flanges 222 and the
slots 220
enables the anchors-100-4 to be pivoted about a vertical axis (e.g., 226) for
purpose of
installation. In this regard, the anchor includes a plate from which arcuate
wall penetrating
retainers 228 extend. In this arrangement the retainers 228 would extend
horizontally
within the wall rather than vertically as in the case of the aforementioned
intermediate
anchor embodiments. Identical anchor components 100-4 can be used on the
opposite
sides of the standard 10 if the two anchor components are inverted relative to
each other.
[0070] Figs. 34-35 show an embodiment in which the intermediate anchor
assembly 100-5 includes side plates 230 with respective retainers 232, where
the side plates
230 are interconnected by a U-shaped portion 234 sized to fit about the
standard 10. The
U-shaped portion 234 includes rearwardly extending fingers 236 that fit within
the standard
slots 14.
[0071] Figs. 36-37 show an embodiment in which the intermediate anchor
assembly 100-6 is integrated with the standard 10-6, and is formed by lateral
flanges 240
and 242 that extend from the sides 16 and 18 of the standard 10-6. Each flange
includes a
respective anchor component 244, 246 mounted thereon. The flanges may be
formed
unitary with the standard sides and bent outward, or may be formed separately
and then
welded thereto.
[0072] Figs. 38-39 show an embodiment in which the anchor assembly 100-7
is
integrated with the standard 10-7 by a hinge pin 250 internal of the channel
of the standard
10-7. The anchor component 257 has a plate 252 with a lower end having a hinge
loop 254
about the hinge pin 250 such that the anchor component is permanently mounted
to the
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standard 10-7. After the standard is positioned against the wall, a tool 256
may be used to
shift the anchor component from its forward position (Fig. 39) to its install
position (not
shown) in which the anchor component retainer 258 is inserted within the wall.
The tool
256 includes a push panel 260 and rearward protruding prongs 262 that pass
through
respective openings 264 in the front side of the standard to move into contact
with the plate
and rotated the plate toward the wall. The tool may be retained in the
standard, or may be
removable.
[0073] Figs. 40-41 show an embodiment in which two identical intermediate
anchor assemblies 100-8 are engaged with the standard 10 above and below each
other, and
with the anchor assemblies 100-8 inverted relative to each other. Each anchor
assembly
100-8 includes a U-shaped body 400 about that fits about the standard and
retainers 402
protruding from the rear edges of the side portions of the body 400. Tabs 404
protrude
from the front plate of the main body 400 and fit with the standard slots 14.
As shown, the
tabs of the two anchor assemblies 100-8 extend in opposite vertical
directions, as do the
retainers 402, due to the relative inversion.
[0074] Referring now to Figs. 42-46, a template system useful for
installation of the
storage system components, specifically the hang brackets and the intermediate
anchors, is
show. The system includes a template 300 comprised of a sheet material having
a plurality
hang bracket positioning slots or openings 302 therein and a plurality of
intermediate
anchor positioning slots or openings 304 therein. In the illustrated
embodiment hang
bracket edge slots 302 are provided and fully circumscribed intermediate
anchor openings
304 are provided. The sheet material has a folded configuration (e.g., Fig.
42) for package
insertion and an unfolded configuration (e.g., Fig. 43) for system install. In
the illustrated
embodiment the folded configuration includes three panel portions 306, but
variations are
possible. Suitable fold lines (e.g. perforations, cuts or scores) may be
formed in the sheet
material to facilitate the fold.
[0075] The sheet material is configured such that in the unfolded
configuration the
sheet material has a generally rectangular shape with a horizontal dimension X
and a
vertical dimension Y, where the horizontal dimension X is larger than vertical
dimension
Y. Edges 308 and 310 of the sheet material are substantially linear (with the
exception of
any slots or cutouts) and run substantially parallel with dimension X. When
the sheet
material is placed adjacent a wall 8 with the edge 310 of the sheet material
placed on the
ground (e.g., as per Figs. 43 and 4), each intermediate anchor positioning
slot or opening
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304 is located at a respective, desired intermediate anchor install location
on the wall. The
abutment between the floor and the sheet edge 310 effectively levels the
template and
assures that all intermediate anchor assemblies will be positioned at desired
heights.
Intermediate anchor assembly 100 is shown being installed in one opening 304
in Fig. 44.
Once a first intermediate anchor assembly is installed the interaction between
the opening
304 and the installed anchor assembly will assure that the remaining openings
304 are
spaced as needed for the desired lateral spacing between vertical standards.
[0076] After all of the intermediate anchor assemblies have been
installed, the
template 300 can then be repositioned such that edge 310 of the sheet material
is facing
upward and each intermediate anchor positioning slot or opening 304 is aligned
over one of
the installed intermediate anchor assemblies (e.g., per Figs. 45 and 46). Each
hang bracket
positioning slot or opening 302 will then be located at a respective, desired
hang bracket
install location on the wall 8, which in the illustrated embodiment is
vertically aligned
above one of the intermediate anchor install locations. The hang brackets 20
can then be
installed in the slots 304. Once all the hang brackets 20 are installed, the
standards can be
hung from the hang brackets and engaged with the intermediate anchors. Cap
members,
shelf brackets, shelves and other components can then be installed as desired
to define the
final storage system configuration.
[0077] Fig. 47 shows a plan view of an alternative template 300-1, in
which both
long edges 308-1 and 310-1 include slots, with edge 308-1 including hang
bracket
positioning slots 302-1 and with edge 308-1 including multiple support slots
320-1. In this
arrangement, for purpose of component installation edge 310-1 is placed on the
ground and
anchor assemblies are installed at the intermediate anchor positioning
openings 304-1. The
template is then lifted upwards and the support slots 320-1 positioned over
the tops of the
installed anchor assemblies (e.g., with edge 301-1 still facing downward),
which then
raised the hang bracket positioning slots 302-1 to the desired heights for
hang bracket
install.
[0078] Fig. 34 also depicts horizontal fold lines 322 in the sheet
material, horizontal
separation lines 324 in the sheet material and vertical separation lines 326
in the sheet
material. By way of example, where the sheet material is formed of a
corrugated plastic
material, the fold lines 322 may be comprised of perforations in just one
surface or layer of
the corrugated plastic while the separation lines may be comprised of
perforations in both
surfaces or layers of the corrugated plastic. However, other variations are
possible.
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[0079] After the template 300-1 has been used to install the hang
brackets and
intermediate anchors, it can be removed from the wall and broken down for use
in the shelf
system. In particular, the sheet material can first be separated along lines
324 and the
upper and lower segments of the sheet material discarded. The remaining sheet
material
can be separated along separation lines 326, which are spaced apart to define
shelf depth
size shelf liner units. After the shelf brackets have been installed on the
standards (e.g., per
shelf brackets 202 in Fig. 1) and suitable interconnecting shelf racking
(e.g., wire form
racking) has been supported between two or more shelf brackets, the shelf
liner units can
be placed onto shelves as shelf liners as shown in Fig. 1.
[0080] While the above template embodiment contemplate templates having a
collapsed configuration in the form of a folded configuration and an expanded
configuration in the form of an unfolded configuration, it is recognized that
other variations
are possible. For example, the template could have a collapsed configuration
in the form of
a rolled configuration and an expanded configuration in the form of an
unrolled
configuration.
[0081] Thus, the template system provides a method of installing a wall
mounted
storage system including shelves, where the method includes: utilizing a
template of sheet
material that includes a plurality of openings spaced and positioned for
defining storage
system component locations on a wall; positioning the template adjacent the
wall and
installing storage system components at positions defined by the template;
removing the
template from the wall; installing additional storage system components
including at least
first and second shelf units; breaking down the template into at least a first
shelf liner and a
second shelf liner; and positioning the first shelf liner on the first shelf
unit and positioning
the second shelf liner on the second shelf unit.
[0082] In any of the foregoing anchor assembly embodiments, the wall
penetrating
retainers can also be configured with other advantageous features.
[0083] For example, to facilitate manual wallboard penetration and
passage without
tools, utilizing thumb or palm force only, the wallboard penetrating retainers
may be
formed with a relatively smooth external surface finish (e.g., achieved by
polishing,
painting, plating or other coating). In this regard, the surface of the
wallboard penetrating
retainers can be manufactured with or modified to a maximum average surface
roughness
of about 20 inch (e.g., in some cases a maximum average surface roughness of
about 15
inch). In one implementation, just the end portion of the wallboard
penetrating retainers
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are worked, processed or otherwise formed to achieve this desired low surface
roughness
feature in order to reduce manufacturing cost. The latter implementation would
reduce
install force but maintain friction on the rougher portions of the penetrating
retainer to
resist removal forces. The retainers may have a polished surface finish and/or
a plated
surface finish and/or a painted finish and/or a lubricant (e.g., Teflon)
incorporated into the
surface finish.
[0084] The wallboard penetrating retainers may also be configured such
that the
distal end of each wallboard penetrating retainer is shaped to provide a
point. Proper sizing
of the wallboard penetrating retainer(s) can also be used to achieve more user
friendly
performance of an anchor. In particular, in some implementations when the
anchor
assembly is installed at the front surface of the wallboard, the distal ends
of the wallboard
penetrating retainers may be positioned proximate to the rear surface of the
wall without
penetrating the paper layer at the rear surface. The cross-sectional sized of
the retainers
can be selected as suitable for manual installation.
[0085] The anchor assemblies can generally be installed without the use
of tools
(e.g., by user thumb force to rotate the anchor component) and provide a very
beneficial
load support capability once installed. Moreover, upon removal of the anchor
from the
wall the size of the hole(s) that are left for repair will be small, which (i)
makes it simpler
for the novice homeowner to make a clean wall repair with as little as just
paint fill and (ii)
more readily allows for slight repositioning of the anchor (e.g., in close
proximity to the
existing holes) if needed.
[0086] It is to be clearly understood that the above description is
intended by way
of illustration and example only, is not intended to be taken by way of
limitation, and that
other changes and modifications are possible. For example, the anchors could
be formed
with snap in place retainers (e.g., wire form retainers that snap into place
on metal or
plastic plate) or the anchors could be produced using an overmold process
(e.g., an
overmold to connect retainers to a plastic plate or an overmold of the metal
plate and
retainer combination). Moreover, while installation of the anchors into walls
of a friable
type (e.g., wallboard) are primarily described, it is recognized that the
anchors could be
mounted to walls of more dense material. For example, the anchors could be
installed into
walls of wood material by pre-drilling holes for each retainer of suitable
size such that,
when the retainer passes into the pre-drilled hole it wedges within the hole.
19
