GB2493572A

GB2493572A - Modular storage system

Info

Publication number: GB2493572A
Application number: GB201117307A
Authority: GB
Inventors: Frank James Hardie; Michael Field
Original assignee: Individual
Current assignee: Individual
Priority date: 2011-08-09
Filing date: 2011-10-07
Publication date: 2013-02-13
Also published as: GB201115825D0; GB201113692D0; GB201117307D0

Abstract

The present invention provides a modular (pigeon-hole) storage system 1 suitable for filing or sorting mail that comprises a plurality of shelves and divider walls defining a matrix of compartments, wherein the matrix is assembled from compartment modules 1A-D that are each formed from one or more extruded plastic tubes. Also provided is a method of making said modular storage system wherein the method comprises forming a plurality of lengths of tube by extrusion, each to serve as a respective compartment module of the system to be assembled side-by-side to form the matrix of compartments. Preferably each length of tube has at least one elongate groove 3 running longitudinally of the tube along its exterior surface by which each compartment module may be coupled to an adjoining compartment module via a male/male connecting element 4 or a co-operating rib 3B. Interior elongate grooves 5 allow for the placement of shelving or dividing walls.

Description

Pigeon-Hole Storage System

Field of the Invention

The present invention concerns improvements in and relating to pigeon hole systems.

Background of the InvenUon

Pigeon hole storage systems are a key element of many mail handling set-ups in offices as well as mail sorting centres although they have a variety of other uses such as, for example, for filing or sorting papers or other media including CDs and DVDs. Pigeon hole storage systems are quite distinct from more generic shelving systems. They are generally more complex and difficult to mass-manufacture than the basic shelving systems such as book shelves and the like. They are characterized by a generally regular matrix of storage volumes, normally small compartments or cubicles that are at least open at the front, which are provided in an upstanding rack or vertical array, normally by using interlocking shelves and vertical divider panels. They may be fabricated of wire frame panels or folded and welded sheet metal or assembled from timber or fibre-board panels. In general the existing fabrication options entail machining and assembly of the individual vertical and horizontal panels and they invariably involve a substantial amount of time and labour both in their formation and their assembly and are thus generally costly.

The present invention seeks to provide an improved shelving system! pigeon hole storage system and a method of forming and method of assembhng such a system that are efficient and substanUafly enhance speed of production and/ or assenibHy Cu the system, h&ping to drive down the currently high costs of pigeon hole storage systems.

Summary of the Invention

According to a first aspect of the present invention there is provided a shelving system! pigeon-hole storage system that comprises a plurality of shelves and divider walls defining a matrix of compartments, wherein the matrix is assembled from compartment modules that are each formed individually from one or more extruded tubes.

In one embodiment each tube is integrally formed being extruded as a whole tube. In another preferred embodiment that we have found to be particularly practical, each tube is extruded as a pair of longitudinally extending halves! longitudinal sections that assemble together with longitudinal edges adjoining each other. These edges may have complementary male and female mating features. For example, one edge may have a male feature such as a rib and the complementary edge of the adjoining longitudinal section may have an elongate female feature such as groove! channel to receive the rib.

Furthermore, the male feature! rib may have a shape that slidingly fits and engages in the groove! channel from one end whereby the longitudinal sections are coupled together but may be disengaged by sliding one longitudinally relative to the other.

According to a second aspect of the present invention there is provided a method of making a pigeon-hole storage system that comprises a plurality of shelves and divider walls defining a matrix of compartments, wherein the method comprises forming a plurality of lengths of tube by extrusion, each to serve as a respective compartment module of the system to be assembled side-by-side to form the matrix of compartments. The extrusion process may be continuous or may be run in batches. The extrusion is preferably of plastics but may be of any other suitable material.

The method preferably further comprises a step of assembling the compartment modules side-to-side (ie wall-to-wall, and which may include top-side of one module coupled to bottom-side of another module) to form the matrix of compartments. In a preferred embodiment a tube is extruded and cut to the required length as it exits the extruder whereby the depth of each compartment corresponds to the thus formed length of tube. Alternatively a tube may be extruded and then divided into the required lengths (suitably substantially equal lengths) whereby the depth of each compartment corresponds to the length of tube. Preferably the extruded tube is a rectangular tube whereby each compartment module is rectangular.

Preferably each length of extruded tube has at least one elongate feature running longitudinally of the tube along its inside and! or outside surface.

Suitably each length of extruded tube has a plurality of said elongate features, with at least one on each external face or quadrant. In a preferred embodiment each length of extruded tube is extruded to have at least one said elongate feature running longitudinally of the tube along its outside surface as an elongate engagement feature by means of which each compartment module may be coupled to an adjoining compartment module in assembly of the matrix.

Suitably the at least one said elongate feature of each length of extruded tube (compartment module) engages with a complementary engagement feature on an adjoining compartment module to couple directly therewith. Alternatively the elongate feature of a first one of an adjoining pair of compartment modules engages with a first complementary engagement feature of a bi-directional connector element and an elongate feature of the other of the pair of adjoining compartment modules engages with a second complementary engagement feature of the bi-directional connector element whereby the adjoining compartment modules are coupled together.

Preferably the elongate engagement feature comprises a male feature with a head portion that will engage within a female feature that has a complementary shape to the head portion whereby the male head portion slidingly engages in the female feature from one end. Suitably the connector element is double-headed with a respective male feature! head projecting in each direction that engages with an elongate female feature of a respective adjoining compartment module to couple a pair of adjoining compartment modules together.

As a further preferred aspect each length of tube may be extruded to have at least one internal elongate feature running longitudinally of the tube along its inside and which in use may detain an end of a sub-divider panel to allow each compartment to be subdivided if required.

As will be appreciated, the system is modular in nature and the modules and any inter-connectors can be manufactured very quickly and economically.

Whether the extrusion process is run substantially continuously or in batches the compartment modules can be produced at rates that far exceed the rates that pigeonhole compartments are normally formed and each full pigeonhole assembly system may be assembled very quickly from any desired number of the modules simply by using the coupling features on the modules either for direct coupling, or indirect coupling using a connector element as described.

Furthermore, the compartment modules being pre-formed at a factory prior to shipping to users provide for different and in some respects better flexibility in stock handling and management than conventional panel built pigeon hole systems.

Where a separate connector element is used, the connector element may also be extruded. This may be as long as the tube lengths! compartment depths but is effective when shorter and saving on material usage. Conversely where it is desired to increase the depth of existing compartments the matrix array or one or more compartment modules may be extended rearwardly by coupling another compartment module behind it with the separate connector element and this may be thus optionally be even longer than the depth of one compartment module.

The system can be free-standing or may be mounted to a wall or other surface for support or stabilization. Other accessories that may be provided with the shelving system include modified mounting brackets suitable for slidingly engaging with the engagement features, eg grooves or ribs, of the modules or of the connector elements for mounting or securing to walls or other surfaces.

These may be moulded as unitary mouldings. Alternatively a length of single-headed connector element may be extruded with a substantially planar rear mounting surface to be adhered or otherwise securely fixed to an otherwise conventional wall mounting bracket, thereby adapting the conventional bracket to slidingly engage with the engagement feature of the modules or of the connector elements.

The bracket may suitably be of a right angle form having an upright member to lie against a wall to be screwed, bolted or otherwise fixed to the wall and a beam at the top of the upright that projects away from the wall as a horizontal support for the shelving system and optionally further having a support strut spanning the angle between the upright and the beam. Further modified wall mounting brackets may be provided that are hinged to allow for greater versatility in mounting options.

Brief Description of the Drawings

Preferred embodiments of the invention will now be more particularly described, solely by way of example, with reference to the accompanying drawings in which: Figure 1 is an end elevation view of a compartment module of a first preferred embodiment of the invention; Figure 2 is a perspective view of a group of four compartment modules assembled side-to-side in a vertical matrix to form a pigeon-hole shelving system; Figure 3 is a perspective view of a sding connector element for inter-connecting adjoining compartment modules; Figure 4 is a perspective view of a wall-mounting bracket with an integrai sding connector element for coupling a compartment module to the bracket; Figure 5 is an end elevation view of a compartment module of a second preferred embodiment of the invention in disassembled state; Figure 6 is a perspective view of the compartment module of Figure 5 in disassembled state; Figure 7 is a partial front elevation view of a variant of the compartment module at the abutment to an adjacent module, here lacking external groves or ribs but adapted to be inter-connected by an end edge connector; Figure 8 is a perspective view of a U-shaped end edge connector to couple together the modules of the Figure 7 variant; Figure 9 is a perspective view of a the U-shaped end edge connector fitted to the modules front end edges, coupling them together; and Figure 10 is a front end elevation view of a compartment module section that is provided with ribs on its external faces for coupling to adjoining compartments.

Description of the Preferred Embodiment

Referring firstly to Figures 1 to 3, the illustrated preferred embodiment of the invention comprises a pigeon-hole storage system 1 that may be floor-, desk-or wall-mounted. The illustrated pigeon-hole storage system 1 comprises a matrix of four pigeon-hole compartments that is assembled from a corresponding number of compartment modules 1 a-d.

The four compartments are not assembled from discrete shelf panels and upright divider panels. They are instead pre-formed as compartment modules la-d, where each module la-d is a length of rectangular tube, suitably of plastics, formed by an extrusion manufacturing process and having a topside wall, bottom-side wall and opposing vertical sidewalls between, but being open front and back. Each tube is integrally formed being extruded as a whole tube.

The length of the tube can be defined to suit the desired depth of the compartment modules. The tube may be extruded and cut to the required length as it exits the extruder whereby the depth of each compartment corresponds to the thus formed length of tube. Alternatively a tube may be extruded and then divided into the required lengths (suitably substantially equal lengths) whereby the depth of each compartment corresponds to the length of tube.

The walls of the extruded tube as shown in Figure 1 are honey-combed, being formed with a number of parallel longitudinal voids! shafts 2 for greater strength to weight ratio. In addition, the tube externally has a number of elongate slots! grooves 3 that run longitudinally of the tube and which are provided in pairs on each of the four external faces of the rectangular tube. These slots! grooves 3 are for coupling the modules la-d together.

Referring to Figure 3, an extruded strip that serves as a bi-directional double-headed connector element 4 is provided as part of the system. This has a butterfly-like profile having a pair of triangular head' portions 4a, 4b and which engages with each of a pair of adjoining compartment modules la, lb to couple the pair of adjoining compartment modules la, lb together. Each external slot! groove 3 is shaped to have a triangular profile, spreading at the base, to be able to slidingly co-operatively receive and engage a head 4a, 4b of the connector element 4. For example, a first head 4a of the connector element 4 is slidingly inserted into an end of an external groove 3 of the first module Ia and pushed therealong while the other head 4b of the connector element 4 is slidingly inserted into an end of a corresponding groove 3 of an adjoining second module lb, thereby coupling the two modules la, lb together.

Internally each tube length! module la-d has a number of wide U-shaped slots! grooves 5 running longitudinally of the tube along its inside and which in use may each serve to detain an end of a sub-divider panel to allow each compartment to be subdivided if required. These sub-divider panels may be flat boards! panels that are also extruded and may be twin-wall and honeycomb! cellular in form. A similar panel may be provided to serve as a back wall to a module! compartment la and may have peripheral mounting features! tabs projecting from its edges (some optionally at right angles to the back wall panel) each to engage in a respective slot! groove 3 or slot 5 of the module! compartment la.

In a preferred example of the pigeonhole system for mail, each tube length! module la-d is of approximately 1mm thick PVC in honeycomb! cellular twin-walled form. For many mail uses it may have width dimension of the order of to 600mm -eg 350mm wide. It may have height dimension of the order of to 400mm high -eg 225mm high. It may have length! depth dimension of the order of 200 to 500mm, eg 300mm long! deep. However other dimensions may be suitable and the dimensions may vary to suit a range of end uses.

Referring to Figure 4, this shows a wafl-mounting bracket 6 with an integral triangular sliding connector element head 6a for shdingly coupling a compartment moduie la-Id to the bracket 6. The iflustrated bracket 6 is of a right angle form having an upright member 6b to lie against a wall to be screwed, bolted or otherwise fixed to the wall and a beam 6c at the top of the upright 6b that projects away from the wall as a horizontal support for the shelving system 1 and further having a support strut Gd spanning the angle between the upright 6b and the beam 6c. Further modified wall mounting brackets may be provided that are hinged to allow for greater versatility in mounting options.

In a second preferred embodiment, illustrated in Figures 5 and 6, each tube that defines a pigeonhole compartment is extruded as a pair of identical longitudinally extending [-end profile halves! longitudinal sections 10 each with a pair of longitudinal edges ba-b, whereby two sections 10 can assemble together with the longitudinal edges bOa, lOb of one adjoining the longitudinal edges ba, lOb of the other. These sections 10 are suitably extruded from one extruder in respective common lengths and then one rotated' about its long axis relative to the other section so that the two sections 10 face each other to assemble together as a tube.

Each longitudinal section 10 has a L-shaped or right angle form! profile like an angle-iron with a first part! wall transitioning to a second part! second wall at an angle to the first wall (here one wall is orthogonal to the other). A first longitudinal edge ba of each section 10, has a male mating feature and a second longitudinal edge lOb of each section 10 has a complementary female mating feature. In the illustrated example, the first edge ba has a male feature comprising a rib 11 and the second edge lOb has an elongate female feature comprising a groove! channel 12 to receive the rib 11 of an adjoining section.

The rib 11 has, like the aforementioned connectors between modules, a head shape (here triangular with broad base outermost) that slidingly fits and engages in the (triangular) groove! channel from one end whereby the longitudinal sections are coupled together but may be disengaged by sliding one longitudinally relative to the other. Both extruded sections 10 are identical, having the same arrangement of slots! channels 3 to receive a head 4a of a separate connector element 4.

In a variant of the embodiment of Figures 5 and 6 that is illustrated in Figure 8 one of the mating extruded sections 10 has male elongate protrusions! ribs 3b instead of the elongate female slots! channels 3 that the other section 10 has.

Accordingly an extrusion section of Figure 5 with female slots! channels 3 on its external faces can not only couple to an extruded section 10 of the Figure 8 type by the edge lOa, lOb rib-in groove coupling to form the pigeonhole compartment but the external faces of the compartment can also be joined to an adjacent compartment by the lateral ribs 3b engaging in the lateral slots! channels 3 of the abutting external face of the adjacent compartment. The section's external faces may have any number of slots! channels 3 and! or protrusions! ribs 3b. In variants each section 10 may have a mixture of slots! channels 3 and protrusions! ribs 3b on each face, eg alternately having a slot 3 then a rib 3b across the face.

The varied arrangements of channels 3 and ribs 3b may be applied not only to section extrusions 10 but also unitary tubular extrusions, such as that of the Figure 1 embodiment, rather than using separate connector elements.

A wide range of other embodiments of the invention may also be provided, within the scope of the claims hereinafter.

Where separate connector elements are used these need not solely be configured to join the compartments by their external faces but may also join them by their internal faces and! or end edges Referring to Figures 7 to 9, a further connector means for coupling adjoining compartments comprises a U-shaped end edge connector 13 that can be mounted onto the front or rear end of a pair of pigeonhole modules! compartments 1 straddling the end edges of adjoining compartment sidewalls to bind! clip them together. The end edge connector 13 has a pair of legs 13a, 13b that each slot into an internal groove 5 of a respective one of the adjoining modules! compartments 1 to bind them together securely.

The novel general approach of the present invention enables a pigeon-hole storage system to be made and assembled with a fraction of the time and labour hitherto required and allows for considerable cost economies in production and assembly. L1