TECHNICAL FIELD

[0001] The invention relates most generally to barrel racks, and more particularly to wine barrel racks, and. still more particularly to a compactly nestable and economically transportable wine barrel rack.

BACKGROUND ART

[0001] In wine production, when fermentation has been completed and after large solids have been removed by racking, the young wine usually needs time for the acids, alcohol, tannins, and glycerin to knit together, to harmonize. Accordingly, it is a traditional practice to barrel age and store the wine for a period of time. This can be accomplished using a number of different kinds of vessels or containers, such as stainless steel tanks, cement vats, glass carboys, or, in most instances, wood barrels. The traditional wood barrel material is oak (indeed, nearly all fine wines, almost without exception, are aged in oak) because it adds depth and complexity by adding phenols and oak tannins to the wine, and. thereby adds new bouquet and. flavor dimensions. Aging in oak also softens grape tannins, increases volatile acidity and total acidity, and lowers pH. Stored the right amount of time, wine aged in oak barrels is generally considered to be improved.

[0002] In consequence, large scale producers often keep hundreds to many tens of thousands of barrels in storage in production and storage facilities, generally either in barrel rooms or wine caves. The racks, however, cover a considerable amount of floor space.

Furthermore, they are generally assembled by welding square steel tubing with steel bars to make unitary, assembled, rigid and fixed racks of the kind taught by Ray. US Pat. No.

3,476,260, which shows a wine rack design that dominates the industry at present. See, for instance, the various models offered at the website links by the following major current-day manufacturers:

[0003] http://www.topcoproducts.com/

[0004] http://www.westernsquare.com/breweries and dis tills eries/brewery barrel racks, html

[0005] http://shop.carolinavvinesupply.com/Wme-Ban-el-Racks_c34.htm

[0006] http://barrelsandracks.com/racks/

[0007] http://www. rmswinebarrelracks.com/wine -barrel-racks/

[0008] http://barrel-racks,com/?page_id= 18

[0009] http://shop . carolinawinesupply . com/ W ine-Barrel-Racks c34.htm

[0010] http://barrelsandracks.com/racks/

[0011] From these, it will be seen that the rack dominant in the industry is a rigid square steel tube welded structure based on structural chocks welded onto square tube steel frame structure. The tube members are all welded together, and the bent steel bars forming wedges that act as chock are welded onto the tubes. The smallest units for stacking systems generally hold two barrels and stack atop two barrels. Bottom units simply cradle two ban-els on top. Even this smallest structure consumes considerable space when assembled, and. welded, and thus when shipped. And stacking for shipment simply means that a substantial portion of the shipping volume is occupied by empty space.

[0012] As the South Napa Earthquake of August 24, 2014 revealed, when racks are severely damaged in earthquakes, they are not amenable to repair and generally must be replaced. Fabrication of the conventional and traditional racks is time consuming and shipments are expensive. High demand taxes the ability of manufacturers to meet winery demand for the needed stackable, palletized and forkiift compatible barrel racks. Now, in the immediate aftermath of the South Napa Earthquake, there will be many shipments of replacement racks required to address the losses. Among other things, this natural tragedy has highlighted the need for a more compact rack, easily manufactured, easily and economically transported, and also easily dismantled for removal and relocation.

DISCLOSURE OF INVENTION

[0002] The present invention solves the foregoing problems by providing a low cost, easily manufactured, easily transported, and easily on-site assembled barrel rack that includes nesting component parts that ship in compact packages,

[0003] The wine barrel rack of the present invention advantageously exploits known principles of strengthening thin sheet metal panels by introducing bends and. cutouts in the panels. Thus, the barrel support function of what was previously pro vided by a very heavy and clumsy structure - rigid, unitary, preassembled tubular steel wine barrel racks - can now be provided by extremely lightweight structural members that can be shipped as modular packages, easily handled, carried, and moved by individuals having unexceptional (entirely ordinary) strength.

[0004] In its most essential aspect, the present invention is a wine barrel rack that includes first and. second ground, level side rails oriented generally parallel to one another. The side rails are joined to one another with either sheet metal panel connecting members or tubular metal connecting members. The rack is assembled with nuts and bolts. Each of the side rails include an upper bend forming a flange and a lower bend forming a flange so as to enhance the strength of the panels. Barrel shaped cutouts are disposed on the upper edge of the side rails in a ground configuration of the rack, and on both upper and lower edges in an upper rack configuration. The cutouts may be in a generally stacked pattern, wherein upper cutouts are immediately above lower cutouts, or in a staggered pattern.

[0005] Other novel features which are characteristic of the invention, as to organization and method of operation, together with further objects and advantages thereof will be better understood from the following description considered in connection with the accompanying drawing, in which preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood, however, that the drawing is for illustration and description only and is not intended as a definition of the limits of the invention. The various features of novelty which characterize the invention are pointed, out with particularity in the claims annexed, to and. forming part of this disclosure. The invention resides not in any one of these features taken alone, but rather in the particular combination of all of its structures for the functions specified.

BRIEF DESCRIPTION OF ΤΪ-ΪΕ DRAWINGS

[0006] The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

[0007] FIG. 1 is an upper front left perspective view of the ground level configuration of the wine barrel rack of the present invention, shown supporting a single wine barrel ;

[0008] FIG. 1 A is a detailed upper front left perspective view taken along cut line 1 A of FIG. 1 ;

[0009] FIG, IB is an exploded view of the apparatus of FIG. 1 ;

[0010] FIG, 2A is an upper left front perspective view showing the sheet metal side rails and connecting panels of the inventive rack, nuts and bolts removed, disassembled, and poised for compact packing for transport or storage;

[0011 ] FIG. 2B is an upper front left perspective view showing the rack elements in a compact nested, configuration;

[0012] FIG. 3A is a side view in elevation showing a sheet metal side rail after cutting but before bending, wherein the bend lines are shown with dashes;

[0013] FIG, 3B is the same view showing the side rail after the upper and lower bends have been made:

[0014] FIG. 3C is an end view in elevation of the side rails; [0015] FIG, 4 is a top plan view of a panel of slieet metal showing the football-shaped cutouts which, when the side rails are cut long the dashed cut lines, will provide the arcuate depressions in the side rails for barrel support;

[0016] FIG, 5 shows the ground level configuration of the inventive rack holding two wine barrels and a stacked layer of the inventive rack atop the lowest level of barrels and upon which is a second row of barrels;

[0017] FIG, 6A is an upper front left front perspective view showing the stacked configuration;

[0018] FIG. 6B is an upper left front perspective view showing details of the connection between a side rail and a connecting panel;

[0019] FIG. 7A is an upper perspective view showing the stacked configuration disassemble, the nuts and bolts removed, and the side rails and connecting panels positioned for nesting in a compact packaged configuration for storage and transportation;

[0020] FIG, 7B shows the elements of the stacked configuration in a compact nested package for storage and transportation;

[0021 ] FIG. 8 is an upper front left perspective view of the ground level configuration of an embodiment of the wine barrel rack of the present invention, shown supporting a single wine barrel ;

[0022] FIG. 9 shows the ground level configuration of the inventive rack holding four wine barrels and a stacked layer of the inventive rack atop the lo west level of barrels and upon which is a second row of barrels, partially filled;

[0023] FIG, 10A is a side view in elevation showing a sheet metal side rail after cutting but before bending, wherein the bend, lines are shown with dashes;

[0024] FIG. 10B is the same view showing the side rail after the upper and lower bends have been made;

[0025] FIG. IOC is an end view in elevation of the side rails;

[0026] FIG. 1 1 is a top plan view of a panel of sheet metal showing the modified football-shaped cutouts which, when the side rails are cut long the dashed cut lines, will provide the arcuate depressions in the side rails for barrel support in an embodiment of the present invention;

[0027] FIG. 12 A is a side view in elevation showing in another embodiment a sheet metal side rail of the upper (stackabie) rack side rail after cutting but before bending, wherein the bend lines are shown with dashes;

[0028] FIG, 12B is the same view showing the side rail after the upper and lower bends have been made;

[0029] FIG. 12C is an end view in elevation of the upper (stackabie) rack side rails;

[0030] FIG. 13 is a top plan view of a panel of sheet metal showing the modified and staggered football-shaped cutouts for the embodiment shown in FIGS. 9, and FIGS. 12A- 12C, which, when the side rails are cut long the dashed cut lines, will provide the arcuate depressions in the side rails for barrel support in this embodiment of the present in vention; and

[0031] FIG, 14 is a side view in elevation showing the ground level configuration and upper (stackable) rack configuration in use, combined so as to enable a stacked and staggered arrangement of barrels as viewed from the side of the rack (corresponding to the end of the barrels).

BEST MODE FOR CARRYING OUT THE INVENTION

[0032] Referring first to FIGS. 1 through 14, wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved nesting transportable wine barrel rack generally denominated 10 herein.

[0033] Looking now at FIG. 1 , there is shown in perspective view the ground level configuration 10 of the barrel rack of the present invention, shown assembled and supporting a single barrel. The ground level of the rack includes a first side rail 12 and a second side rail 14 joined at their ends 12a/12b and 14a/14b, respectively, by first and second connecting end panels 16, 18. and a medial connecting panel 20, The side rails are identical to one another, as are the connecting panels. Accordingly, in discussing these elements, attention is drawn to one as representative of the others.

[0034] Thus, it is seen that each ground level side rail 12/14 includes a plurality of upper arcuate cut outs 22, each suitable for supporting or cradling a wine barrel when paired with a cutout on the opposing side rail, as shown in FIG. 1.

[0035] Each side rail further includes an outwardly directed lower betid or flange 24, and an outwardly directed upper bend or flange 26, continuous but for interruptions at the upper arcuate cutouts, and thereby comprising a formed sheet.

[0036] The connecting panels 16/18/20 are each U-shaped with end legs 28 and through holes 30 that align with through holes 32 in the side rails for connection with nuts and bolts 34, 36. respectively. Washers 38 are preferably employed, for all the well-known reasons.

[0037] It will be noted, by reference to each of FIGS. 1-1B, that the connecting panels 16, 18, 20, are slightly less wide (lower profile) than the side rails 12, 14, Accordingly, and referring now to FIGS. 2A-2B, if the side rails are turned on their longitudinal (horizontal axis) such that the lower flange 26 and upper flange 26 are facing, they are positioned to couple around the connecting panels in a nested configuration 40 (FIG. 2B) for storage and transport.

[0038] The inventive barrel rack system has another distinct advantage having to do with the simple, rapid, and economical method of manufacture. Because they formed of sheet metal and the manufacture process includes only a few quick fabrication steps, these racks can be rapidly manufactured on demand, and. therefore no appreciable inventory need be stored anywhere.

[0039] FIG. 4 shows a sheet metal panel 50 partially processed during manufacture of the ground-level rack elements. In this view, the sheet metal panel is shown marked along dotted cut lines 52 for cutting with a laser, water jet, bench (lever) shear, guillotine (squaring or power shear), etc. A plurality of football-shaped holes 54 have already been cut from the panel using a laser or water jet, and bolt holes 56 have been punched or drilled. After the football holes are cut and the bolt holes drilled, the panel is cut along the cut lines 52 and then upper and lower flanges (26, 24, respectively, in FIGS. 1 -2B) are bent using a press brake or, more preferably, a universal bending machine.

[0040] Connecting panels 16, 18, 2Θ are formed from a separate raw sheet of sheet metal, and then drilled and bent similarly.

[0041] FIGS. 5-7B show another embodiment 60 of the inventive rack, this embodiment adapted for stacking at either the ground level or at levels above ground level, including atop a row of barrels. Thus, when a ground level rack 10 is disposed on a cellar floor and a number of barrels WB are placed on the ground level rack, the stackable (upper) rack 60 may be placed atop the barrels on the ground level rack.

[0042] The stackable rack 60 includes first and second side rails 62, 62 joined at their ends 62a/62b and 64a/64b, respectively, by first and second connecting end panels 66, 68, and a medial connecting panel 70. The side rails are identical to one another, as are the connecting panels.

[0043] Each stackable side rail 62/64 includes a plurality of arcuate cut outs 72, each suitable for supporting or cradling a wine barrel when paired with a cutout on the opposing side rail, as shown in FIG, 5, and also suited for stacking atop barrels positioned below. Unlike the ground level embodiment, the stackable rails include arcuate cutouts on each longitudinal edge of the rail. Thus, the rails may be rotatated about a longitudinal axis, and with the flange or bend 74 facing outward, the rail may be flipped over and used in an inverted orientation (as can the assembled rack).

[0044] As with the first embodiment, U-shaped connecting panels 66/68/70 again include legs 78 and through holes 80 that align with through holes 82 in the side rails for connection with nuts 84, bolts 86, and w ^r ashers 88.

[0045] Forklift holes 90 are provided in the side rails.

[0046] The rack elements are each preferably formed from stainless steel, and more preferably with 300 series austenitic stainless steel, though any of a number of kinds of stainless steel and aluminum panel kinds may be employed to provide a rack with sufficient structural integrity and corrosion resistance to handle the heavy loads borne by racks in which barrels are stacked 4 or more levels high in slightly acid and humid cellar environments.

[0047] The stackable rack is also capable of compact storage in nestable packs 100, thus making it fit for large shipping unassembled in large numbers so as to be able to meet the needs of an end user at low cost and in quick order.

[0048] In another embodiment of the present invention, shown in FIGS. 8-1 1, the ground level configuration 200, includes side rails 202. 204 joined near or at their ends, respectively 206a/206b and 208a/208b (208b being concealed in FIG 8), by first and second cross supports 210, 212, and at least one (preferably several) medial cross support(s) 214. The side rails are identical to one another, as are the cross supports.

[0049] Thus, it is seen that each ground level side rail 202/204 includes a plurality of arcuate cut outs 216, each suitable for supporting or cradling a wine barrel when paired with a cutout on the opposing side rail, as shown in FIGS, 8-9.

[0050] Each side rail farther includes an outwardly directed lower bend or flange 218, and an outwardly directed upper bend or flange 220, continuous but for interruptions at the arcuate cutouts, and thereby comprising a formed sheet.

[0051] The end cross supports 210/212 and medial cross supports 214 are each fabricated from square or rectangular tube (steel, aluminum, alloys, etc.) with an integral and/or welded flange 222 and through holes that align with through holes in the side rails for connection with nuts and bolts 224, respectively, the holes concealed by the nut/bolts assemblies, but evident in the views. The cross supports for the ground level configuration further include legs 226 to elevate the entire rack off the ground and provide clearance for water and wine to run freely out from under the assembly and for the forks of a forklift to fit under easily for easy and. rapid movement of entire racks within a production facility.

[0052] This embodiment of the wine barrel rack of the present invention includes an enhanced cutout having notches 228 onto which chocks 230 with slots are disposed so as to provide support and cushioning in the arcuate cradle formed by the cutouts 216. The chocks are fabricated from a food grade resilient material, such as silicone or other suitable synthetic rubber product so as to minimize any chance that the assembly will harbor microorganisms that might infect and destroy the beverage contained in the barrels,

[0053] FIG. 1 1 shows a sheet metal panel 240 partially processed during manufacture of the ground-level rack elements. In this view, the sheet metal panel is shown marked along dotted cut lines 242 for cutting with a laser, water jet, bench (lever) shear, guillotine

(squaring or power shear}, etc. A plurality of football-shaped holes 244 have already been cut from the panel using a laser or water jet, and bolt holes 246 have been punched or drilled. After the football holes are cut and the bolt holes drilled, the panel is cut along the cut lines and then upper and lower flanges (218, 220, respectively in FIGS. 8, 10A & 10C) are bent using a press brake or, more preferably, a universal bending machine.

[0054] Cross supports 210, 212, 214 are formed from separate metal tubes and then drilled and provided with flanges.

[0055] FIG. 9 shows an upper (stackable) rack configuration 250 for use with the above described lower rack configuration. This upper rack configuration is adapted for stacking at levels above ground, level, including atop a row of barrels. Thus, when the ground level rack 200 (FIG. 8) is disposed on a cellar floor and a number of barrels WB are placed on the ground level rack, the stackable rack 250 may be placed atop the barrels ground level barrels.

[0056] The upper (stackable) rack 250 is configured substantially identically to the ground level configuration with a few notable exceptions, clearly seen in FIG. 9, and better appreciated by reference to FIGS. 12A-14, where it is seen that the upper (stackable) rack 250 includes side rails 252, 254 joined near or at their ends, respectively 256a/256b and 258a/258b (258b being concealed in FIG. 9), by first and second cross supports 260, 262, and. at least one (preferably several) medial cross support(s) 264. Notes should, be taken that medial cross supports 264 are secured at an angle such that the sides and top portions of the cross supports are oriented at an angle generally coincident with the curved sides of a wine barrel. The side rails are identical to one another, as are the cross supports.

[0057] Thus, it is seen that in this embodiment each upper rack side rail 252/254 includes a plurality of upper and lower arcuate cut outs 266a and 266b, respectively, the upper arcuate cut outs adapted for supporting or cradling a wine barrel and bearing its weight, and. the lower cut outs 266b adapted for placement over a wine barrel. The upper and lower cutouts are arranged in a staggered pattern, such that the lower cutouts re disposed under and generally centered between two adjoining upper cutouts.

[0058] Each side rail further includes an outwardly directed lower bend or flange 268, and an outwardly directed upper bend or flange 270, continuous but for interruptions at the arcuate cutouts, and thereby comprising a formed, sheet.

[0059] The end cross supports 260/262 and medial cross supports 264 may be fabricated, trom square or rectangular tube (steel, aluminum, alloys, etc.) with an integral and/or welded flange 272 and through holes that align with through holes in the side rails for connection with nuts and bolts 274, respectively, the holes concealed by the nut/bolts assemblies, but evident in the views. The cross supports for the upper rack configuration do not include legs to elevate the rack off the ground, as clearance for water and. wine, for the forks of a forklift, and. the like, is inherent in the elevated disposition of the rack when placed atop a wine barrel, [0060] This embodiment of the wine barrel rack of the present invention also includes the enhanced cutout having notches 278 onto which upper chocks 280a and lower chocks 280b, each with slots, are disposed. Again, these provide support and cushioning in the arcuate cradle formed by the cutouts 266a/266b.

[0061] FIG. 13 shows a sheet metal panel 290 partially processed during manufacture of the ground-level rack elements. In this view, the sheet metal panel is shown marked along dotted cut lines 292 for cutting. Football-shaped holes 294 for the enhanced cutouts have already been cut from the panel using a laser or water jet, and bolt holes 296 have been punched or drilled. After the football holes are cut and the bolt holes drilled, the panel is cut along the cut lines and then upper and lower flanges (268, 270, respectively in FIGS. 9, 12A & 12C) are bent.

[0062] Cross supports 260, 262, and 264 are formed from separate metal tubes and then drilled and provided with, flanges.

[0063] FIG. 14 shows a three-level stack including the ground level configuration and two upper rack configurations as might be found in a wine barrel room or wine cave. This view features the staggered arrangement of barrels (as viewed from the side or barrel end view of the rack), which facilitates access to the bung at the apex of the barrel . This view also shows how optional vertical supports 300 may be installed at the ends 256a/256b, and 258/258b of the side rails to provide further support and stability to the rack assembly.

[0064] The above disclosure is sufficient to enable one of ordinary skill in the art to practice the invention, and. provides the best mode of practicing the invention presently contemplated by the inventor. While there is provided herein a full and complete disclosure of the embodiments of this invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like.

[0065] Therefore, the above description and illustrations should not be construed as limiting the scope of the invention, which is defined by the appended, claims.