TECHNICAL FIELD

[0001] This application relates generally to wall mounted shelves, and related systems, methods and components.

BACKGROUND

[0002] Numerous wall mounted shelf products exist. Conventional products are difficult to install and/or lack a desirable combination of aesthetic features and ability to support relatively heavy weights. This is particularly true in the case of thin profile shelves such as traditional floating shelves.

[0003] It would be desirable to provide shelf units and systems that better meet both the aesthetic and functional needs of end consumers.

SUMMARY

[0004] In one aspect, a wall mountable shelf system includes anchor components that are easily installed, without the use of tools, and one or more shelf components configured to facilitate hiding the anchor components.

[0005] 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

[0006] Fig. 1 shows a perspective view of one embodiment of a wall mountable shelf system;

[0007] Fig. 2 shows a perspective view of the shelf system with plugs and anchors not shown;

[0008] Fig. 3 is a front elevation of Fig. 2;

[0009] Fig. 4 is rear elevation of Fig. 2;

[0010] Fig. 5 is a side elevation of Fig. 1;

[0011] Figs. 6-8 show views of an anchor component;

[0012] Fig. 9 shows a partial cross-section within a recess;

[0013] Fig. 10 shows a partial cross-section of another recess embodiment;

[0014] Fig. 11 shows a side profile of another plug configuration;

[0015] Figs. 12-13 shows perspective views of another embodiment of a wall mountable shelf system; [0016] Fig. 14 shows a partial perspective of an anchor component and shelf recess for engaging the anchor component;

[0017] Fig. 15 shows a side elevation of a shelf and anchor component, with anchor recess and hook slot also shown;

[0018] Fig. 16 shows the shelf and anchor component of Fig. 15 after shelf mounting on the anchor component;

[0019] Figs. 17-19 are perspective view of another embodiment of a wall mountable shelf system;

[0020] Fig. 20 is a partial perspective showing anchor receiving recesses of the shelf unit of Figs. 17-19;

[0021] Figs. 21-23 show a front elevation, cross-section and bottom view respectively of the shelf unit of Figs. 17-19;

[0022] Figs. 24 and 25 show exploded perspective views of another embodiment of a wall mountable shelf system;

[0023] Fig. 26 shows a rear view of the mount frame of the shelf system;

[0024] Figs. 27 and 28 show assembled perspective views of the shelf system;

[0025] Figs. 29 and 30 show perspective views of the shelf system with rear panel removed;

[0026] Fig. 31 shows a cross-section of the shadow box unit of the shelf system;

[0027] Figs. 32 and 33 show exploded perspective views of another embodiment of a wall mountable shelf system;

[0028] Figs. 34 and 35 show assembled perspective views of the shelf system; and

[0029] Figs. 36 and 37 show an alternative mount anchor embodiment.

DETAILED DESCRIPTION

[0030] 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. The shelf systems described herein may also be installed on harder types of walls, such as wood walls. [0031] Referring to Figs. 1-11, a wall mountable shelf system 10 is shown and includes a shelf unit 12 having a wall panel 14 and a shelf panel 16. In the illustrated embodiment the wall panel and shelf panel are monolithically formed (e.g., of plastic or fiber board) with the shelf panel 16 adjoin the wall panel 14 via a curved section 18.

However, other shelf unit configurations are possible. The wall panel 14 has a front side 20 and a rear side 22. The rear side abuts against a wall surface upon mounting of the shelf unit and maybe substantially planar (or have plural coplanar surface segments) for such purpose. The shelf panel 16 extends outward and forward from the front side of the wall panel 14 and defines an upper shelf surface 24 for supporting one or more objects. The front side 20 of the wall panel 14 includes at least one mount recess 26 (e.g., one or more, in this case four mount recesses, though the number may vary). Each mount recess 26 includes at least one (e.g., one or more, here two) anchor through openings 28 passing from the front side to the rear side of the wall panel. An anchor component 30 can be positioned in each recess and have wall penetrating retainers that extend through each opening 28 for mounting the shelf unit to the wall.

[0032] Each mount recess 26, and the anchor component therein, may be covered by a corresponding recess plug 32. For this purpose each recess plug 32 may have a profile shape that substantially matches a profile shape of the mount recess (e.g., in this case both profiled shapes are rectangular, but other shapes could be used such as rounds, ovals of triangles or diamonds). The recess plug may also, in some implementations, have a depth, extending from its front side to its rear side, that substantially matches a depth of the mount recess less the depth or thickness of the anchor base, enabling the front side of the recess plug 32 to sit flush with the front side of the wall panel 14 when fully pressed into the recess and engages with the front side of the anchor. In implementations where it is desired to conceal the recess plugs 32 as much as possible, each recess plug may have a front side surface texture and appearance that substantially matches a surface texture and appearance of the front side of the wall panel. In other implementations, such as where it is desired to utilize the recess plugs 32 to provide an aesthetic affect, each recess plug may have a front side surface texture and/or appearance that is distinct form the surface texture and/or appearance of the front side of the wall panel. For example, the plugs 32 may be of a different color or may have a design element imprinted thereon. The mount recesses 26 and corresponding plugs 32 may also be arranged in an aesthetic pattern on the front side of the wall panel if desired. [0033] The illustrated anchor components 30 are in the form of a planar base member 40 (e.g., of metal plate) having front, back, top, bottom, left and right sides, and at least one (e.g., one or more, here two) wall penetrating retainers 42 extending from the base member and having a rearwardly extending portion with curved configuration. At least a wall penetrating extent 43 of each retainer 42 may be arcuate and the radius of curvature R defined by may have a center point 45 that is proximate the bottom side of the planar base portion 40.

[0034] In anchor component use, the back side of the planar base portion 40 seats against an outward facing surface 44 of the mount recess 26 when the anchor component is installed in position for wall mounting, and the wall penetrating retainers pass through the anchor through openings 28 and penetrate the wall 100 to which the shelf unit 12 is mounted (e.g., see dashed line anchor configuration 30' in Fig. 9). To achieve this position, the anchor 30 is positioned in the recess with the bottom side adjacent the lower recess surface and then rotated about the bottom side (per arrow 47) to move the retainers into the wall 100 (e.g., by a user applying a pushing force F at the front of the base portion 40). The plug 32 may then be inserted. The above-mentioned arcuate retainer extent geometry minimizes the energy and force required to insert each set of anchor retainers, minimizes damage to the wall and results in small wall surface perforations when the anchor is removed.

[0035] In the illustrated embodiment, each wall penetrating 42 retainer is curved in a downward direction when the anchor component 30 is moved to the mount position within the mount recess 26. Per Fig. 9, the recess surface 44 may be angled relative to a plane of the wall 100 when the shelf unit 12 is adjacent the wall, with the outward facing surface 44 angling away from the wall plane when moving from a top of the outward facing surface to a bottom of the outward facing surface. This angled configuration enables the wall penetrating retainers 42 to take make a more aggressive entry into the wall 100 to which the shelf unit is to be mounted. To better match this general recess configuration, the plugs may have a similar varying thickness as suggested by the plug 32' shown in profile in Fig. 11. Of course, other recess variations are possible, such as that shown in Fig. 10 where the outward facing recess surface 44' is substantially parallel with the wall surface.

[0036] Referring now to Figs. 12-16, a wall mountable shelf system 210 includes a shelf unit 212 having a shelf panel 216 with a front side 220 and a rear side 222, the rear side for abutting against a wall surface upon mounting. A side panel 250 of varying depth extends downward from one side of the shelf panel 216 and a side panel 252 of varying depth extends downward from an opposite side of the shelf panel 216. A bottom panel 260 of relatively short depth may extend between the bottoms of the two side panels to form an enclosed configuration with a passage 262 through which the wall can be viewed. In the illustrated embodiment the shelf panel 216 has a depth that is substantially greater than a depth of the bottom panel 260 (e.g., at least three times as deep) and the side panels are tapered so as to reduce in depth when progressing from the shelf panel downward to the bottom panel.

[0037] Each of the side panels 250, 252 includes a rear side for abutting the wall surface upon mounting. The side panels 250, 252 also include an anchor feature to facilitate mounting of the shelf to the wall by an anchor component. In this regard, each side panel may include a respective anchor engaging slot 254 at its rear side, where the slot includes an entry part 256 and an internal retention part 258. Each entry part 256 extends normal to the rear side of the panel and each retention part 258 extends upward within the panel. The slots 256 enable the shelf unit to be supported by hooks 244 that engage into the slots (e.g., where the hooks may be located on respective anchor components).

[0038] In this regard, each anchor component 230 of the system may be in the form of a planar base member 240 having front, back, top, bottom, left and right sides, and at least one wall penetrating retainer 242 extending from the base member and having a rearwardly extending portion with a curved configuration. The back side of the planar base portion seats against an outward facing surface of a wall for mounting and a hook element 244 projects forwardly from the base member 240 and is sized to be received in the shelf unit slots 254. The wall penetrating retainers 242 may be curved in a downward direction when the anchor components 230 are installed in the wall, and have arcuate wall penetrating extents as described above. Each anchor engaging slot 254 may be located within a recess 255 at the rear side of the respective side panel, where the recess 255 is sized to receive and surround the anchor component so that the shelf unit sits flush against the wall and the anchor components are hidden upon mounting. Regardless of whether the recesses are present, an entirety of each anchor component may be covered by its respective side panel. Each anchor component 230 (as well as component 30 above) may be formed as a monolithic unit from a metal plate material that is cut to shape and then bent into the desired final configuration. However, variations in which the retainers are formed separately and then connected to the planar base member (e.g., by welding) are also contemplated.

[0039] Once a pair of anchors are mounted to a wall, the shelf unit 212 can be moved onto the anchors by aligning the slots 254 with the hooks and moving toward the anchors (to move the hooks into the entry portions of the slots) and then down (once the hooks reach the retention portion of the slots), per arrow 257 in Fig. 15. Removal of the shelf unit 212 simply requires a reverse operation (up and outward away from the anchor and wall 100). Providing additional anchor components (e.g., a set of two vertically spaced apart anchor components for engaging with side panel 250 and another set for engaging with side panel 252) would provide increased strength in terms of shelf support.

[0040] In an alternative arrangement, improved shelf support performance can be achieved by locating the anchor component hook toward the bottom of the base member as suggested by the proposed hook 244' shown in dashed line form in Fig. 15, in which case the anchor slots 254 would be located toward the bottoms of the recesses 255 instead of toward the tops. Moreover, the anchor could be of two-piece form, with two anchor components hinged together in an overlapping manner and having an install orientation in which the retainers create a jaw-like gripping action in the wall 100, per the anchor assembly 600 shown in Figs. 36 and 37. This anchor assembly includes angled side flanges 602 that are oriented to allow a properly shaped recess or bracket of a shelf component to slide down over the anchor assembly into engagement with the flanges 602 with a wedging action that pulls the shelf component toward the wall.

[0041] Referring now to Figs. 17-23, a wall mountable shelf system 310 includes a shelf unit 312 having a shelf panel 316 with a front side 320 and a rear side 322, the rear side for abutting against a wall surface upon mounting. A side panel 350 extends downward from one side of the shelf panel 316 and a side panel 352 extends downward from an opposite side of the shelf panel 316. No bottom panel is provided in the illustrated embodiment, but implementations with a bottom panel are possible. The shelf panel 316 includes a bottom side with at least one (e.g., one or more, here two) upwardly extending anchor receiving recesses 370 therein. Each anchor receiving recess 370 is bounded at its rear side by a retention wall 372. Each retention wall 372 has a plurality of anchor through openings 328 therein extending to the rear side of the shelf panel. At least one, (e.g., one or more, here two in each recess) of anchor components 330 are positionable within the anchor receiving recess(es) 370. Each anchor component 330 may be of a similar form to the anchor component 30 described above, with a planar base member 340 having front, back, top, bottom, left and right sides, and at least one wall penetrating retainer 342 extending from the base member and having a rearwardly extending portion with a curved configuration. The back side of the planar base member seats against a front surface of the retention wall 372 and the wall penetrating retainers 342 each pass through one of the anchor through openings 328. In the illustrated embodiment, the wall penetrating extent of each wall penetrating retainer 342 is curved in a lateral direction when the anchor component 330 is installed in the wall with the shelf horizontal. In the illustrated install orientation the curved retainers of each pair of anchor components in a given recess 370 curved toward each other, as best seen in Fig. 23, in a jaw-like gripping action. Jaw-like gripping action can also be achieved by anchor components installed in separate recesses as opposed to both anchor components being in the same recess.

[0042] In the illustrated embodiment the forward facing surface of each retention wall 372 is generally planar and parallel to the back side of the shelf unit that seats against the wall. However, in an alternative embodiment the jaw-like gripping action could be enhanced by angling the retention wall forward surface (e.g., as suggested by dashed line 372' in Fig. 23) so that the retainers of the anchor components engage the wall more aggressively.

[0043] Referring now to Figs. 24-31, a wall mountable shelf system 410 is shown and includes a mount frame 412 and a shadow box unit 414. The mount frame 412 includes a plurality of interconnected walls 416 forming an enclosed configuration. The illustrated embodiment has four main walls defining an enclosed configuration that is square-shaped, but other variations are possible such as triangles (3 walls), pentagon (5 walls), hexagons (6 walls) etc. Each wall 416 includes a front edge 418, a rear edge 420, an inner side 422 and an outer side 424. A rear wall 417 is also provided. The rear wall 417 includes one or more anchor through openings 428 through which an anchor component retainer can extend for mounting the mount frame 412 to a wall. In the illustrated embodiment the rear wall 417 includes two pair through openings 428, but variations are possible. Moreover, embodiments in which the rear wall is only a partial wall or flange are also possible.

[0044] The shadow box unit 414 includes a plurality of interconnected walls 440 forming an enclosed configuration that matches the enclosed configuration of the mount frame. Each wall 440 of the shadow box unit includes a front edge 442, a rear edge 444, an inner side 446 and an outer side 448. The inner sides 446 of the walls 440 are arranged to permit the shadow box unit 414 to slide onto the mount frame unit 412 with the walls 440 in contact with the walls 416 of the mount frame unit to frictionally retain the shadow box unit on the mount frame unit (e.g., in a slight friction fit or in a substantial friction fit).

[0045] Each wall 440 of the shadow box unit has a thickness THl at its rear edge, a thickness TH2 at its front edge, where THl is greater than TH2. As shown, each wall 440 has a drafted configuration with a continuous taper from the thickness THl to thickness TH2. The continuous taper in thickness is achieved at the external side of each wall 440. In particular, as best seen in Fig. 31, the inner sides 446 of opposed walls 440 of the shadow box unit are substantially parallel to each other, while the outer sides 448 of the opposed walls 440 are not.

[0046] Anchor components 430, which may be of similar construction and configuration to anchor components 230 and 30 above, have a planar base member with front, back, top, bottom, left and right sides, and a set of penetrating retainers 452 extending from the base member and having rearwardly extending wall penetrating extents. The planar base member seats against a front surface of the rear wall 417 of the mount frame 412, and the wall penetrating retainers 452 pass through respective ones of the anchor through openings 428 and into a wall. In the illustrated embodiment two anchor components 430 are utilized to mount the frame unit 412 a wall (not shown), but the number could vary. In terms of install, the mount frame unit 412 is positioned at a desired location on a wall. The anchor components are then pushed (e.g., manually) so that the retainers move through the openings 428 and penetrate the wall. The shadow box unit can then be slid onto the mount frame unit. If desired, a rear panel 470 can then be positioned internally of the shadow box 414 and mount frame unit 412 and positioned adjacent the rear wall 417 of the mount frame unit to cover the anchor components for aesthetic effect. The panel 470 may simply be sized to be frictionally held in place.

[0047] While the illustrated shelf system 410 includes only two anchor

components, additional anchor components could be provided for increased support. For example, additional vertically oriented anchor components could be provided, and or laterally oriented anchor components (e.g., similar to those shown below for shelf system 510) could be provided, in either case at a variety of different heights and/or lateral positions along the rear wall 417. [0048] Referring now to Figs. 32-35, another wall mountable shelf system 510 including a mount frame 512 with side walls 516 and rear flanges 526, where the rear flanges 526 together make up a rear wall that is a partial rear wall. A shadow box unit 514 includes side walls 540 and a rear wall 517, which may be fixed or removable. In this embodiment, each wall of the shadow box unit has a scalloped or tapered front portion 562 and a rear portion of substantially uniform thickness. In this embodiment a depth of the rear portion is substantially greater than a depth of the scalloped front portion. The mount flanges 526 of the illustrated mount frame 512 project inwardly from the mount frame and may be formed unitary with the rest of the mount frame (e.g., where the mount frame is of bent metal sheet material). The anchor components 530 may be similar to those described above. In the illustrated embodiment the top flange 526 include two sets of openings 528 and the side flanges each include one set of openings 528. The anchor components 530 that engage the top flange can be installed so that the curved retainers will extend downwardly within a wall (not shown) and the anchor components 530 that engage the side flanges can be installed so that the curved retainers extend laterally within the wall (e.g., with the retainers of the two spaced apart side anchor components extending toward each other). The rear wall 517 of the shadow box unit covers the anchor components when the shadow box unit 514 is inserted within the mount frame 512.

[0049] In relation to the anchor components proposed above for the illustrated shelf systems, the wallboard penetrating retainers can be configured with advantageous features to facilitate use and operation. For example, to facilitate manual wallboard penetration and passage without tools, utilizing thumb force only, the wallboard penetrating retainer may be formed with a relatively smooth external surface finish (e.g., achieved by polishing, painting or plating). 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 μίηϋΐι (e.g., in some cases n a maximum average surface roughness of about 15 μίηϋΐι). In one implementation, just the wallboard penetrating extent of each wallboard penetrating retainers is 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. [0050] The wallboard penetrating retainers may, as shown, include a pointed tip that is shaped to provide a point when viewed in cross-section taken along a plane running along a length of the wallboard penetrating retainer, where the point is defined by a bevel at a bottom side of the distal end of the wallboard penetrating retainer and/or side bevels. Proper sizing of the wallboard penetrating retainer(s) can also be used to achieve more user friendly performance of an anchor. In one example, low insertion forces for the retainer(s) of a given anchor component may be achieved where the retainers have pointed distal ends as described above and a generally uniform cross-section along the remainder of the wall penetrating extent of the retainer, where an area of the cross-section is no more than about 2.5 mm ² . Regardless of whether one or multiple retainers are used, it may be advantageous (e.g., for the purpose of ease of install and/or for the purpose of limiting wall damage) to assure that the total retainer cross-sectional area of any one anchor component (e.g., the cross-sectional area of one retainer if only one is used or the total cross-sectional area of two retainers if two retainers are used) is no more than about 5 mm ² (about 0.008 square inches, or in some cases no more than about 6 mm2), where the cross-section of each wall penetrating extent of the retainer is taken perpendicularly to a lengthwise axis of the retainer (which axis is curved like the retainer) and is taken at any location along a length of the wall penetrating extent of the retainer that will embed within a wall.

[0051] Generally each of the above shelf system embodiments provides a configuration in which the anchor components are spread out. Moreover, each shelf unit or shadow box provides a relatively large amount of vertical engagement on the wall surface, which reduces pull out force on the anchor components due to the shelf load cantilever forces. More typical thin profile floating shelves do not provide this feature. This allows the shelf or shadow box to support more weight. The systems also enable installation without the use of tools. Moreover, no anchoring hardware is visible after installation. Utilization of anchor components of the type described also enables end users to more easily adjust shelf position and/or repair anchoring holes in the wall when the shelf system is moved or removed.

[0052] 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 anchor components could be formed with snap in place retainers (e.g., wire form retainers that snap into place on metal or plastic base) or the anchors could be produced using an overmold process (e.g., an overmold to connect retainers to a plastic base or an overmold of the metal base of a metal base and retainer combination).