Flat Rack with Extender

This patent application is a Continuation application of U.S. patent application Ser. No. 17/954,863, filed Sep. 28, 2022, which is currently pending, the entire teachings and disclosure of which are incorporated herein by reference thereto. This patent application claims the benefit of U.S. Provisional Patent Application No. 63/253,832, filed Oct. 8, 2021, the entire teachings and disclosure each of which are incorporated herein by reference thereto.

This invention generally relates to retail display systems and adjustable racks for retail display systems.

Retail display systems such as shelving systems are used for displaying merchandise. One particularly shelving system is a refrigerated case that has one or more shelves for displaying merchandise. Some refrigerated cases often have a well formed at a bottom region thereof. The bottom most shelf, which may also be referred to as a rack, often covers a portion of the well that holds components of the system such as pumps, controllers, electrical wiring, hoses, refrigeration components, etc.

Overtime, dust, dirt, grime, and product can get into the well and below the bottom most shelf. Further, maintenance is often required on the components of the system stored below the bottom most shelf. Easy and efficient access to the region below the bottom most shelf can make cleaning easier and more cost effective.

Often, the bottom most shelf is provided by a wire shelf made from interconnected pieces of round wire. Typically, the surface area of these shelves have a greater percentage of openings than surface area provided by the wires. This can make these shelves difficult to clean. For example, it is quite often required to clean around the wire rather than simply clean a flat surface, making complete cleaning difficult.

Further, by being made from wire, these shelves can be relatively heavy.

Further, these wire shelves typically require entire removal of the shelf from the display system to access the well below the shelves. One problem when an entire shelf is removed, it may be difficult to remember the proper orientation to reinstall the shelves. This is particularly true if the person cleaning the shelf is not the person who originally staged the shelving system or that has to reassemble the shelving system after cleaning. For instance, it is quite often that the person cleaning the shelving system is not the person who reassembles the shelving system as the shelving system may need a period of time to dry prior to reassembly.

In some systems, there are plenums below the bottom most product shelf/rack that cover components of the system as noted above (e.g. pumps, fans, hoses, controllers, etc.). In prior systems, it was often necessary to retire the entire bottom most shelf to provide access to or movement of the plenums to allow for cleaning thereunder.

Examples of the present application provide improvements over the current state of the art for shelving systems and particularly shelving systems that have a well formed at the bottom region thereof.

In an example, an adjustable rack system for mounting to a frame assembly of a shelving unit is provided. The adjustable rack system includes an adjustable frame and an adjustable rack. The adjustable frame includes a front rail, a rear rail and at least one longitudinally adjustable rail. The rear rail is spaced from the front rail. The longitudinally adjustable rail interconnects the front and rear rails. The at least one longitudinally adjustable rail is longitudinally adjustable in length to adjust the spacing between the front and rear rails along an adjustment axis. The adjustable rack is removably attached to the adjustable frame. The adjustable rack includes a first panel defining a rear edge of the adjustable rack and a second panel defining a front edge of the adjustable rack. The second panel is adjustably positionable relative to the first panel to adjust a spacing between the front and rear edge of the adjustable rack. The adjustable rack defines a top surface defined in part by each of the first and second panels.

In one example, the at least one longitudinally adjustable rail includes a first and a second side rail that interconnect the rear and front rails. The second side rail is laterally spaced apart from the first side rail. The first and second side rails being longitudinally adjustable to adjust a length thereof parallel to the adjustment axis.

In one example, each of the first and second side rails includes a front side rail member and a rear side rail member. The front side rail member is adjustably positionable relative to the rear side rail member to adjust the length of the corresponding side rail. The front side rail members are attached to the front rail. The rear side rail members re attached to the rear rail.

In one example, the first panel is operably attached to the rear rail and the second panel is operably attached to the front rail such that the first panel and rear rail move together as a unit relative to the front rail and the second panel to adjust spacing between the front and rear edges along the adjustment axis.

In one example, the longitudinally adjustable rail includes a first rail member and a second rail member. The first rail member is attached to the front rail. The second rail member is attached to the rear rail. The second rail member is slidably connected to the first rail member to adjust the length of the longitudinally adjustable rail along the adjustment axis. The first panel is operably attached to the rear rail by being directly attached to the second rail member. The second panel is operably attached to the front rail by being directly attached to the first rail member.

In one example, the first and second panels are removable from the frame simultaneously as a single unit.

In one example, a first panel connector connects the first panel to a rear portion of the adjustable frame. The interaction between the first panel connector and the rear portion of the adjustable frame fixes the first panel relative to the rear portion of the adjustable frame along the adjustment axis. A second panel connector connects the second panel to a front portion of the adjustable frame. The interaction between the first connector and the front portion of the adjustable frame fixes the second panel relative to the front portion of the adjustable frame along the adjustment axis. The front and rear portions of the adjustable frame being movable relative to one another along the adjustment axis.

In one example, the first panel connector is provided by at least one of a pin, a plug, and/or a projection formed by the first panel. The second panel connector is provided by at least one of a pin, a plug, and/or a projection formed by the second panel.

In one example, the first panel includes at least one mounting projection extending downward below the top surface. The at least one mounting projection extends into a mounting aperture formed in a rear portion of the adjustable frame. The interaction between the at least one mounting projection and mounting aperture fixes the first panel relative to the rear portion of the adjustable frame along the adjustment axis. The second panel includes at least one mounting projection extending downward below the top surface. The at least one mounting projection extends into a mounting aperture formed in a front portion of the adjustable frame. The interaction between the at least one mounting projection and mounting aperture fixes the second panel relative to the front portion of the adjustable frame along the adjustment axis. The front and rear portions of the adjustable frame being movable relative to one another along the adjustment axis.

In one example, the rear portion of the adjustable frame is movable relative to the front portion of the adjustable frame along the adjustment axis.

In one example, the first panel includes at least one mounting projection that extends downward below the top surface. The at least one mounting projection extends into a mounting aperture formed in the rear rail. The interaction between the at least one mounting projection and mounting aperture fixes the first panel relative to the rear rail along the adjustment axis. The second panel includes at least one mounting projection that extends downward below the top surface. The at least one mounting projection extends into a mounting aperture formed in the front rail. The interaction between the at least one mounting projection and mounting aperture fixing the second panel relative to the front rail along the adjustment axis.

In one example, the at least one mounting projection of the first panel is formed by an annular wall that surrounds an aperture extending through the first panel and through the top surface. The at least one mounting projection of the second panel is formed by an annular wall that surrounds an aperture extending through the second panel and through the top surface.

In one example, the at least one mounting projections of the first and second panels are sized for receipt of one or more fingers of a user to allow the user to grasp the corresponding first or second panel to remove the adjustable rack from the adjustable frame.

In one example, an intermediate rail extends between and interconnects the first and second side rails. The second panel includes a channel formed in an underside thereof that receives the intermediate rail.

In one example, the first and second panels have a sliding interlock therebetween. When coupled, the sliding interlock permits the first panel to slide relative to the second panel along the adjustment axis but prevents the first and second panels from being disconnected from one another in a direction generally orthogonal to the top surface.

In one example, the sliding interlock includes at least one clip provided one of the first and second panels. The sliding interlock includes a slide region of the other one of the first and second panels that is slidingly engaged by the at least one clip. The slide region being generally parallel to the adjustment axis.

In one example, the slide region includes a notch sized to receive the at least one clip therethrough generally orthogonal to the top surface for assembling the sliding interlock.

In one example, the sliding interlock includes first and second clips provided by one of the first and second panels. The first and second clips are spaced apart from one another in a lateral direction being generally perpendicular to the adjustment axis. First and second slide regions are provided by the other one of the first and second panels. The first clip slidingly engages the first slide region for sliding motion parallel to the adjustment axis but prevents disconnection generally orthogonal to the top surface. The second clip slidingly engages the second slide region for sliding motion parallel to the adjustment axis but prevents disconnection generally orthogonal to the top surface.

In one example, the sliding interlock includes first and second clips provided by the first panel. Each of the first and second clips includes a leg extending downward from a first main panel section of the first panel and a foot portion extending laterally from the leg. The foot and a bottom of the first main panel section forming a channel therebetween. First and second slide regions are provided by a second main panel section of the second panel. The first slide region is received in the channel formed by the first clip. The second slide region is received in the channel formed by the second clip.

In one example, the foot of the first clip extends towards the foot of the second clip. The first and second slide regions are positioned laterally between the legs of the first and second clips.

In one example, the second main panel includes a first notch adjacent the first slide region and a second notch adjacent the second slide region. The first and second notches are sized and configured such that the foot of the first clip can pass through the first notch to align the first slide region with the channel of the first clip and the foot of the second clip can pass through the second notch to align the second slide region with the channel of the second clip.

In one example, the first notch is formed between opposed ends of the first slide region such that a first portion of the first slide region is on a first side of the first notch and a second portion of the first slide region is on a second side of the first notch. The second notch is formed between opposed ends of the second slide region such that a first portion of the second slide region is on a first side of the second notch and a second portion of the second slide region is on a second side of the first notch.

In one example, the adjustable frame includes a first rear frame mount. The first rear frame mount includes an exposed portion that extends rearward of a rear side of the rear rail. The exposed portion includes a downward opening notch. The adjustable frame includes a first front frame mount. The first front frame mount includes an exposed portion that extends forward of a front side of the front rail. The exposed portion includes a downward opening notch.

In one example at least two rear frame mounts or at least two front frame mounts are provided such that at least three frame mounts are provided to improve stability of the adjustable rack system, when mounted to the shelving frame.

In one example, the first rear frame mount is removably attached to the rear rail. The first rear frame mount includes a first leg and a second leg extending from the first leg forming an L-shape. The first leg is longer than the second leg. The downward opening notch is formed in the exposed portion of the first leg. The first leg has a second portion located forward of the rear side of the rear rail. The second portion, at least in part, secures the first rear frame mount to the rear rail. The first front frame mount is removably attached to the front rail. The first front frame mount includes a first leg and a second leg extending from the first leg forming an L-shape. The first leg is longer than the second leg. The downward opening notch is formed in the exposed portion of the first leg. The first leg has a second portion located rearward of the front side of the front rail. The second portion, at least in part, secures the first front frame mount to the front rail.

In one example, the rear rail includes a top wall, a bottom wall vertically spaced from the top wall, and a rear wall below the top wall. The rear wall defines the rear side of the rear rail. The rear wall defines an opening through which the first leg of the first rear frame mount extends. The bottom wall defines an opening through which the second leg of the first rear frame mount extends. The front rail includes a top wall, a bottom wall vertically spaced from the top wall, and a front wall below the top wall. The front wall defines the front side of the front rail, the front wall defines an opening through which the first leg of the first front frame mount extends. The bottom wall defines an opening through which the second leg of the first front frame mount extends.

In one example, the rear rail includes a yoke defining a cavity that receives the second portion of the first leg of the first rear frame mount. The yoke is positioned between the rear wall and the opening in the bottom wall of the rear rail. The opening in the bottom wall of the rear rail is elongated in a lateral direction and sized to permit the first rear frame mount to be rotated from an orientation wherein the second leg is generally horizontal to an orientation wherein the second leg of the first rear frame mount extends vertically downward to insert the second leg of the of the first rear frame mount into the opening in the bottom wall. Insertion of the second leg of the first rear frame mount into the opening in the bottom wall limits motion of the first rear frame mount parallel to the adjustment axis. The front rail includes a yoke defining a cavity that receives the second portion of the first leg of the first front frame mount. The yoke is positioned between the front wall and the opening in the bottom wall of the front rail. The opening in the bottom wall of the front rail is elongated in a lateral direction and sized to permit the first front frame mount to be rotated from an orientation wherein the second leg of the first front frame mount is generally horizontal to an orientation wherein the second leg of the first front frame mount extends vertically downward to insert the second leg of the of the first front frame mount into the opening in the bottom wall. Insertion of the second leg of the first front frame mount into the opening in the bottom wall limits motion of the first rear frame mount parallel to the adjustment axis.

In one example, the yoke of the rear rail extends downward from the top wall of the rear rail and the yoke of the front rail extends downward from the top wall of the front rail.

In one example, the rear rail includes a rear wall. The rear wall defines an opening through which the first rear frame mount extends. The first rear frame mount includes an upward opening notch. The upward opening notch receives a portion of the rear wall forming part of the opening through which the rear frame mount extends. The front rail includes a front wall. The front wall defines an opening through which the first front frame mount extends. The first front frame mount includes an upward opening notch. The upward opening notch receives a portion of the front wall forming part of the opening through which the front frame mount extends.

In one example, the first rear frame mount includes an upward opening notch. The upward opening notch receives a portion of the rear rail. Engagement provided by the notch and the portion of the rear rail prevents movement of the first rear frame mount relative to the rear rail along the adjustment axis. The first front frame mount includes an upward opening notch. The upward opening notch receives a portion of the front rail. Engagement provided by the notch and the portion of the front rail prevents movement of the first front frame mount relative to the front rail along the adjustment axis.

In one example, the top surface of the adjustable rack includes a plurality of upward extending ribs and a plurality of apertures formed therethrough.

In one example, the plurality of upward extending ribs are provided by the first panel and the plurality of apertures are provided by the second panel.

In an example, a frame mount for mounting a rack frame to a shelving unit frame is provided. The frame mount includes a first leg and a second leg extending from the first leg in a first direction forming an L-shape. The first leg is longer than the second leg. A first notch is formed in first leg. The notch opens in the first direction.

In one example, the first and second legs are formed from a continuous piece of material.

In one example, the continuous piece of material is a bent wire.

In one example, a second notch is provided that opens in a second direction being opposite the first direction such that the first and second notches are on opposite sides of the first leg.

In one example, the second notch is located axially along the first leg between the first notch and the second leg.

In one example, the first notch extends axially along the first leg a greater distance than the second notch.

In one example, the second notch is axially offset from the first notch along a length of the first leg.

In an example, a shelving system including a shelving frame an adjustable rack system as outlined above is provided. The shelving frame includes a rear mounting wall and a front mounting wall. The rear mounting wall extends vertically a first height and the front mounting wall extends vertically a second height that is less than the first height. The front mounting wall is spaced forward of the rear mounting wall. The rear mounting wall and front mounting wall form a well therebetween below a top end of the front mounting wall. The adjustable rack is mounted to the rear mounting wall and the front mounting wall with the front edge of the adjustable rack at or below the top end of the front mounting wall of the shelving frame.

In one example, the adjustable rack of the adjustable rack system is removable from the shelving frame without removing the adjustable frame from the shelving frame.