WALL RACK WITH PREFABRICATED BRACKETS AND SUPPORT FRAME

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 63/565,737 filed Mar. 15, 2024, the entirety of which is incorporated herein by reference.

FIELD

The teaching disclosed herein relates to wall mountable storage racks, and more particularly, to a wall rack assembly and kit thereof which include a prefabricated support frame and prefabricated wall brackets.

INTRODUCTION

U.S. Pat. No. 9,635,940 (Letham) purports to disclose an expandable wall storage system designed to provide maximum storage without loss of floor space. The system provides functional storage for bulky items on top, the flexibility to hang items below and the ability to see what is on the shelf through a gridded shelf. The system includes an interface defined by side portions and at least two support brackets of the storage system for engaging an adjacent expandable wall storage system when aligned in a side-by-side relationship. The system allows easy installation and avoids struggles with overhead mounting. The system can be provided in multiple length configurations and further extensions can also be provided.

U.S. Pat. No. 4,603,781 (Ryan, Jr.) purports to disclose a shelf assembly comprising a plurality of parallel spaced platform members and a plurality of spaced frame members fixedly connected to the platform members so as to define a grid-like shelf. Each of the frame members extends normal to the platform members and each has distal ends extending beyond the outermost platform members. A pair of allochirally configurated shelf end support brackets is provided, each end bracket having means for freely supporting the distal ends of the frame members so as to support the shelf in a generally horizontal plane when the support brackets are secured to an associated wall.

SUMMARY

The following summary is intended to introduce the reader to various aspects of the applicant's teaching, but not to define any invention.

According to some aspects, a kit for a wall rack includes (a) a prefabricated first wall bracket, (b) a prefabricated second wall bracket, and (c) a prefabricated rectangular support frame. Each of the first and second wall brackets includes a vertical bar mountable to a wall in a vertical orientation. The vertical bar has a vertical bar proximal end portion and a vertical bar distal end portion opposite the vertical bar proximal end portion. Each of the first and second wall brackets further includes a horizontal bar having a horizonal bar proximal end portion and a horizontal bar distal end portion opposite the horizontal bar proximal end portion. The horizonal bar proximal end portion is welded to the vertical bar proximal end portion. Each of the first and second wall brackets further includes a diagonal bar having a diagonal bar proximal end and a diagonal bar distal end opposite the diagonal bar proximal end. The diagonal bar proximal end is welded to the vertical bar distal end portion. The diagonal bar distal end is welded to the horizontal bar distal end portion. The rectangular support frame includes a frame left bar and a frame right bar spaced apart from the frame left bar by a frame width. The rectangular support frame further includes a frame front bar and a frame back bar spaced apart from the frame front bar by a frame depth. Opposed ends of the frame front bar are welded to respective front ends of the frame left and right bars. Opposed ends of the frame back bar are welded to respective back ends of the frame left and right bars. The frame left bar has a laterally outboard surface directed away from the frame right bar. The frame right bar has a laterally outboard surface directed away from the frame left bar. The support frame is securable to the first wall bracket with the laterally outboard surface of the frame left bar bearing against a laterally inboard surface of the horizontal bar of the first wall bracket. The support frame is securable to the second wall bracket with the laterally outboard surface of the frame right bar bearing against a laterally inboard surface of the horizontal bar of the second bracket.

In some examples, the vertical bar, the horizontal bar, and the diagonal bar of each wall bracket comprise respective lengths of steel square tube.

In some examples, the frame front and back bars comprise respective lengths of steel square tube.

In some examples, the frame left and right bars comprise respective lengths of steel C-channel having an upright web and a flange extending laterally inwardly from a lower end of the web.

In some examples, the support frame further includes a frame middle bar parallel to, and spaced apart from, the frame left and right bars. The frame middle bar has a middle bar front end and a middle bar back end opposite the middle bar front end. The middle bar front end is welded to the frame front bar. The middle bar back end is welded to the frame back bar.

In some examples, the kit further includes at least one elongate crossmember. Each of the crossmembers is releasably securable to the support frame, oriented parallel to, and spaced apart from, the frame front bar and the frame back bar.

In some examples, each of the crossmembers has a crossmember first end portion securable to the frame middle bar and a crossmember second end portion securable to a respective one of the frame left bar and the frame right bar.

In some examples, each of the crossmembers is securable to the support frame at any one of a plurality of depth positions. Each of the depth positions is spaced apart from the frame front bar by a respective depth spacing. The depth spacing of any one of the depth positions is distinct from the depth spacings of the other depth positions.

In some examples, the frame middle bar includes a rail extending upwardly from a rail lower end to a rail upper end, a left flange projecting leftward from a left side of the rail lower end, and a right flange projecting rightward from a right side of the rail lower end.

In some examples, each of the frame left bar and the frame right bar have an upright web and a flange extending laterally inwardly from a lower end of the web.

In some examples, each of the crossmembers is securable to the support frame by connecting the crossmember first end portion to one of the left flange and the right flange of the frame middle bar and connecting the crossmember second end portion to the flange of a respective one of the frame left bar and the frame right bar.

In some examples, respective upper surfaces of each of the frame front bar, the frame back bar, the frame left bar, the frame right bar, and the frame middle bar lie in a common plane.

In some examples, each of the crossmembers has a respective crossmember upper surface that lies in the common plane when the respective crossmember is secured to the support frame.

In some examples, the support frame defines a support frame opening bounded by the frame left and right bars and the frame front and back bars.

In some examples, the kit further includes at least one deck for covering at least a portion of the support frame opening.

In some examples, the kit further includes a first deck for covering a left portion of the support frame opening between the frame left bar and the frame middle bar, and a second deck for covering a right portion of the support frame opening between the frame right bar and the frame middle bar.

In some examples, each of the decks comprises a wire grid.

In some examples, the kit further includes at least one wall brace. Each of the wall braces includes a brace first end portion and a brace second end portion opposite the brace first end portion. The brace first end portion is securable to the vertical bar of the first wall bracket. The brace second end portion is securable to the vertical bar of the second wall bracket.

In some examples, each of the wall braces further includes a plurality of wall mounting apertures spaced apart lengthwise along the wall brace.

In some examples, a first set of the plurality of wall mounting apertures is located proximate the brace first end portion and a second set of the plurality of wall mounting apertures is located proximate the brace second end portion.

In some examples, the vertical bar of each of the wall brackets includes a plurality of brace mounting through holes spaced apart lengthwise along the vertical bar.

In some examples, each of the wall braces includes an elongate brace body having opposed brace body edges. The brace first and second end portions extend perpendicularly from a respective one of the opposed brace body edges. Each of the brace first and second end portions have a pair of vertically spaced apertures alignable with a corresponding pair of the plurality of brace mounting through holes for securing the wall brace to the vertical bar of a respective one of the first and second wall brackets.

In some examples, the horizontal bar of each of the wall brackets includes a plurality of through holes spaced apart lengthwise along the horizontal bar. Each of the frame left and right bars have a plurality of apertures spaced apart lengthwise along a respective one of the frame left and right bars. The apertures of each of the frame left and right bars are alignable with the through holes of the horizontal bar of a respective one of the first and second wall brackets for securing the support frame to the first and second wall brackets.

In some examples, the vertical bar of each of the wall brackets includes a plurality of through holes spaced apart lengthwise along the vertical bar for mounting the wall bracket to the wall.

According to some aspects, a wall rack assembly includes (a) a prefabricated left wall bracket and a prefabricated right wall bracket mountable to a wall in a horizontally spaced apart relation, and (b) a prefabricated rectangular support frame. Each of the wall brackets includes a vertical bar mountable to a wall. The vertical bar has a vertical bar proximal end portion and a vertical bar distal end portion opposite the vertical bar proximal end portion. Each of the wall brackets further includes a horizontal bar having a horizonal bar proximal end portion and a horizontal bar distal end portion opposite the horizontal bar proximal end portion. The horizontal bar proximal end portion is welded to the vertical bar proximal end portion. Each of the wall brackets further includes a diagonal bar having a diagonal bar proximal end and a diagonal bar distal end opposite the diagonal bar proximal end. The diagonal bar proximal end is welded to the vertical bar distal end portion. The diagonal bar distal end is welded to the horizontal bar distal end portion. The support frame is positioned between the horizontal bars of the left and right wall brackets. The support frame includes a frame left bar and a frame right bar spaced apart from the frame left bar by a frame width. Each of the frame left and right bars has a laterally outboard surface. The support frame is secured to the left wall bracket with the laterally outboard surface of the frame left bar bearing against a laterally inboard surface of the horizontal bar of the left wall bracket. The support frame is secured to the right wall bracket with the laterally outboard surface of the frame right bar bearing against a laterally inboard surface of the horizontal bar of the right wall bracket. The support frame further includes a frame front bar and a frame back bar spaced apart from the frame front bar by a frame depth. Each of the frame front and back bars has left and right opposed bar ends welded to a respective one of the frame left and right bars.

In some examples, the support frame further includes a frame middle bar parallel to, and spaced apart from, the frame left and right bars. The frame middle bar has a middle bar front end and a middle bar back end opposite the middle bar front end. The middle bar front end is welded to the frame back bar. The middle bar back end is welded to the frame front bar.

In some examples, the wall rack assembly further includes at least one crossmember. Each of the crossmembers is releasably secured to the support frame, oriented parallel to, and spaced apart from, the frame front bar and the frame back bar.

In some examples, each of the crossmembers has a crossmember first end portion securable to the frame middle bar and a crossmember second end portion securable to a respective one of the frame left bar and frame right bar.

In some examples, each of the crossmembers is securable to the support frame at any one of a plurality of depth positions. Each of the depth positions is spaced apart from the frame front bar by a respective depth spacing. The depth spacing of any one of the depth positions is distinct from the depth spacings of the other depth positions.

In some examples, the frame middle bar includes a rail extending upwardly from a rail lower end to a rail upper end, a left flange projecting leftward from a left side of the rail lower end, and a right flange projecting rightward from a right side of the rail lower end.

In some examples, each of the frame left bar and the frame right bar have an upright web and a flange extending laterally inwardly from a lower end of the web.

In some examples, each of the crossmembers is secured to the support frame by connecting the crossmember first end portion to one of the left flange and the right flange of the frame middle bar and connecting the crossmember second end portion to the flange of a respective one of the frame left bar and the frame right bar.

In some examples, the support frame defines a support frame opening bounded by the frame left and right bars and the frame front and back bars.

In some examples, the wall rack assembly further includes at least one deck for covering at least a portion of the support frame opening.

In some examples, the wall rack assembly further includes at least one wall brace. Each of the wall braces include a brace first end portion and a brace second end portion opposite the brace first end portion. The brace first end portion is secured to the vertical bar of the left wall bracket. The brace second end portion is secured to the vertical bar of the right wall bracket.

According to some aspects, a method of assembling of a wall rack includes securing a left bar of a prefabricated rectangular support frame to a horizontal bar of a prefabricated left wall bracket with a left laterally outboard surface of the left bar bearing against a laterally inboard surface of the horizontal bar of the left wall bracket. The left laterally outboard surface of the left bar is directed away from the right bar of the support frame. The method further includes securing a right bar of the rectangular support frame to a horizontal bar of a prefabricated right wall bracket with a right laterally outboard surface of the right bar bearing against a laterally inboard surface of the horizontal bar of the right wall bracket. The right laterally outboard surface of the right bar is directed away from the left bar of the support frame. The method further includes securing a vertical bar of the left wall bracket to a wall in a vertical orientation and securing a vertical bar of the right wall bracket to the wall in a vertical orientation.

In some examples, the step of securing the vertical bar of the left wall bracket to the wall in a vertical orientation and the step of securing the vertical bar of the right wall bracket to the wall in a vertical orientation are performed before the step of securing the left bar of the rectangular support frame to the horizontal bar of the left wall bracket and the step of securing the right bar of the rectangular support frame to the horizontal bar of the right wall bracket.

In some examples, the step of securing the vertical bar of the left wall bracket to the wall in a vertical orientation and the step of securing the vertical bar of the right wall bracket to the wall in a vertical orientation are performed after the step of securing the left bar of the rectangular support frame to the horizontal bar of the left wall bracket and the step of securing the right bar of the rectangular support frame to the horizontal bar of the right wall bracket.

In some examples, the method further includes securing a left end portion of a wall brace to the vertical bar of the left wall bracket and securing a right end portion of the wall brace to the vertical bar of the right wall bracket.

In some examples, the step of securing the left end portion of the wall brace to the vertical bar of the left wall bracket and the step of securing the right end portion of the wall brace to the vertical bar of the right wall bracket are performed after the step of securing the left bar of the rectangular support frame to the horizontal bar of the left wall bracket and the step of securing the right bar of the rectangular support frame to the horizontal bar of the right wall bracket.

In some examples, the step of securing the left end portion of the wall brace to the vertical bar of the left wall bracket and the step of securing the right end portion of the wall brace to the vertical bar of the right wall bracket are performed after the step of securing the vertical bar of the left wall bracket to the wall in a vertical orientation and before the step of securing the vertical bar of the right wall bracket to the wall in a vertical orientation.

In some examples, the step of securing the vertical bar of the left wall bracket to the wall in a vertical orientation involves mounting the vertical bar of the left wall bracket directly to the wall and the step of securing the vertical bar of the right wall bracket to the wall in a vertical orientation involves mounting the vertical bar of the right wall bracket directly to the wall.

In some examples, the step of securing the vertical bar of the left wall bracket to the wall in a vertical orientation involves mounting the wall brace directly to the wall at a position proximate the left end portion of the wall brace, the step of securing the vertical bar of the right wall bracket to the wall in a vertical orientation involves mounting the wall brace directly to the wall at a position proximate the right end portion of the wall brace, or both.

DRAWINGS

For a better understanding of the described examples and to show more clearly how they may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:

FIG. 1 is a front perspective view of a wall rack assembly according to aspects of the teaching disclosed herein;

FIG. 2 is an exploded front perspective view of the wall rack assembly of FIG. 1;

FIG. 3 is a side perspective view of a prefabricated wall bracket of the wall rack assembly of FIG. 1;

FIG. 4 is a front perspective view of a prefabricated support frame of the wall rack assembly of FIG. 1;

FIG. 5 is a cross-sectional view of a portion of the wall rack assembly taken along line 5-5 of FIG. 1;

FIG. 6 is a front perspective view of a wall brace of the wall rack assembly of FIG. 1;

FIG. 7 is a front perspective view of a crossmember of the wall rack assembly of FIG. 1;

FIG. 8 is a top perspective view of the wall rack assembly of FIG. 1, with crossmembers of the assembly in different depth positions;

FIG. 9 is a front perspective view of the wall rack assembly of FIG. 1, with the wall rack assembly supporting four tires in an upright orientation;

FIG. 10 is a partially exploded front perspective view of the wall rack assembly of FIG. 1, with optional decks aligned for positioning on the support frame of the assembly;

FIG. 11 is a front perspective view of the wall rack assembly of FIG. 1, with the decks of FIG. 10 supported by the support frame of the assembly;

FIG. 12 is a front perspective view of the wall rack of FIG. 1 shown assembled in an alternate configuration; and

FIG. 13 is an exploded perspective view of a kit for a wall rack according to aspects of the teaching disclosed herein.

The drawings included herewith are for illustrating various examples of apparatuses and methods of the teaching of the present specification and are not intended to limit the scope of what is taught in any way.

DESCRIPTION OF VARIOUS EXAMPLES

Various apparatuses or processes will be described below to provide an example of each claimed invention. No example described below limits any claimed invention and any claimed invention may cover processes or apparatuses that differ from those described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an example of any claimed invention. Any invention disclosed in an apparatus or process described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors, or owners do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document.

Referring to FIGS. 1 and 2, a wall rack assembly 100 in accordance with aspects of the teaching disclosed herein includes features that simplify installation and allow for installation in alternate configurations. The wall rack assembly 100 includes a prefabricated left wall bracket 102a, a prefabricated right wall bracket 102b and a prefabricated rectangular support frame 104. In use, the left and right wall brackets 102a, 102b are mounted to a wall in a horizontally spaced apart relation and the support frame 104 is positioned between and secured to the first and second wall brackets 102a, 102b.

The wall brackets 102a, 102b and the support frame 104 are “prefabricated” in that each of these elements requires no further assembly or modification by the installer of the wall rack assembly 100. The prefabricated wall brackets 102a, 102b and the prefabricated support frame 104 can improve the installation process in one or more ways. For example, the number of parts that must be assembled during installation is reduced. This may shorten installation time and/or reduce opportunities for the installer to assembly parts incorrectly. The prefabricated wall brackets 102a, 102b and the prefabricated support frame 104 may also improve the stability of the wall rack assembly 100. The manufacturer-provided, permanent, non-releasable connections (e.g. welding) of the members of the wall brackets 102 and support frame 104 results in a final assembly having fewer connections that are susceptible to loosen, or even fail, over time.

Referring to FIG. 3, each prefabricated wall bracket 102a, 102b includes a vertical bar 106, a horizontal bar 108 and a diagonal bar 110. In the illustrated example, the vertical bar 106, the horizontal bar 108, and the diagonal bar 110 of each wall bracket 102a, 102b comprise respective lengths of steel square tube. In alternative examples, the horizontal bar 108, and the diagonal bar 110 of each wall bracket 102a, 102b may comprise respective lengths of another stock material, such as square plastic tube, square polyvinyl chloride (PVC) tube, etc.

The vertical bar 106 has a vertical bar proximal end portion 112 and a vertical bar distal end portion 114 opposite the vertical bar proximal end portion 112. The horizontal bar 108 has a horizonal bar proximal end portion 116 and a horizontal bar distal end portion 118 opposite the horizontal bar proximal end portion 116. In the illustrated example, the horizonal bar proximal end portion 116 is welded to the vertical bar proximal end portion 112. The diagonal bar 110 has a diagonal bar proximal end 120 and a diagonal bar distal end 122 opposite the diagonal bar proximal end 120. In the illustrated example, the diagonal bar proximal end 120 is welded to the vertical bar distal end portion 114 and the diagonal bar distal end 122 is welded to the horizontal bar distal end portion 118. In alternative examples, the vertical bar 106, the horizontal bar 108 and the diagonal bar 110 may be of unitary construction (e.g., injection molded plastic).

Referring again to FIG. 1, the vertical bar 106 of each wall bracket 102a, 102b is mountable to a wall in a vertical orientation. In the illustrated example, each vertical bar 106 includes a plurality of through holes 124 spaced lengthwise along the vertical bar 106 for securing the wall bracket 102a, 102b to the wall. In installations where the vertical bar 106 overlies a wall stud, the respective wall bracket 102a, 102b can be secured directly to the wall. To secure the wall brackets 102a, 102b directly to the wall, mechanical fasteners (e.g., screws, nails, etc.) are passed through respective through holes 124 and into wall studs. When each wall bracket 102a, 102b is secured to the wall in a vertical orientation, the horizontal bar 108 of the respective wall bracket 102a, 102b extends generally perpendicularly away from the wall.

Referring to FIG. 4, the rectangular support frame 104 includes a frame left bar 126 and a frame right bar 128 spaced apart from the frame left bar 126 by a frame width 130. The rectangular support frame 104 further includes a frame front bar 132 and a frame back bar 134 spaced apart from the frame front bar 132 by a frame depth 136. In the illustrated example, opposed ends of the frame front bar 132 are welded to respective front ends of the frame left and right bars 126, 128, and opposed ends of the frame back bar 134 are welded to respective back ends of the frame left and right bars 126, 128. In alternative examples, the frame left bar 126, the frame right bar 128, the frame front bar 132, and the frame back bar 134 may be of unitary construction (e.g., injection molded plastic).

In the illustrated example, the frame front and back bars 132, 134 comprise respective lengths of steel square tube. In alternative examples, the front and back bars 132, 134 may comprise respective lengths of another stock material, such as square plastic tube, square polyvinyl chloride (PVC) tube, etc. In the illustrated example, with reference to FIGS. 4 and 5, the frame left and right bars 126, 128 comprise respective lengths of steel C-channel having an upright web 138 and a flange 140 extending laterally inwardly from a lower end of the web 138. In alternative examples, the frame left and right bars 126, 128 may comprise respective lengths of plastic angles or plastic C-channels.

Referring again to FIG. 4, each of the frame left and right bars 126, 128 has a laterally outboard surface. The frame left bar 126 has a left laterally outboard surface 142 directed away from the frame right bar 128. The frame right bar 128 has a right laterally outboard surface 144 directed away from the frame left bar 126. In the illustrated example, each of the left and right laterally outboard surfaces 142, 144 is an outboard facing surface of the respective upright web 138 (see FIG. 5).

Referring to FIG. 2, the horizontal bar 108 of each wall bracket 102a, 102b has opposed left and right lateral surfaces 146, 148. In the illustrated example, the support frame 104 is secured to the left wall bracket 102a with the left laterally outboard surface 142 of the frame left bar 126 bearing against the right lateral surface 148 of the horizontal bar 108 of the left wall bracket 102a. In the illustrated example, the support frame 104 is secured to the right wall bracket 102b with the right laterally outboard surface 144 of the frame right bar 128 bearing against the left lateral surface 146 of the horizontal bar 108 of the right wall bracket 102b. When the support frame 104 is secured to the wall brackets 102a, 102b, the left and right lateral surfaces 146, 148 become laterally inboard and laterally outboard surfaces, respectively, according to which of the surfaces bear against the support frame 104.

With reference to FIGS. 2 and 3, in the illustrated example, the horizontal bar 108 of each wall bracket 102a, 102b includes a plurality of through holes 150 spaced apart lengthwise along the horizontal bar 108. Opposite ends of each through hole 150 are respectively formed in the first and second lateral surfaces 146, 148 of the respective horizontal bar 108. In the illustrated example, a first pair of the through holes 150 is located proximate to the horizontal bar proximal end portion 116 and a second pair of the through holes 150 is located proximate to the horizontal bar distal end position 118.

With reference to FIGS. 2 and 4, in the illustrated example, each of the frame left and right bars 126, 128 has a plurality of apertures 152 spaced apart lengthwise along the respective bar 126, 128. Each aperture 152 of the frame left bar 126 is alignable with a corresponding one of the through holes 150 of the horizontal bar 108 of the left wall bracket 102a. Similarly, each aperture 152 of the frame right bar 128 is alignable with a corresponding one of the through holes 150 of the horizontal bar 108 of the right wall bracket 102b. With reference to FIGS. 2 and 5, in the illustrated example, a bolt 210 is passed through the aligned through hole 150 and aperture 152. Subsequently, a nut 212 is threaded onto the terminal end of the bolt 210 and tightened. In alternative examples, other forms of mechanical fasteners may be used to secure the support frame 104 to the wall brackets 102a, 102b (e.g., screws, pins, etc.).

When the wall rack assembly 100 is fully assembled and mounted to a wall, the horizontal bar 108 of each wall bracket 102a, 102b is secured to a respective one of the left frame bar 126 and the right frame bar 128 in a side-by-side configuration (e.g., FIG. 5). In this configuration, the support frame 104 is mounted between, and at the same elevation as, the horizontal bars 108 of the wall bracket 102a, 102b, rather than mounted atop the horizontal bars 108. Mounting the support frame 104 atop the horizontal bars 108 would be a more common configuration, according to those of skill in the art, since such a configuration would transfer the weight of the support frame 104 (and any contents thereon) directly to the wall brackets 102a, 102b, rather than relying on the fasteners 210 to transfer weight from the support frame 104 to the wall brackets 102a, 102b.

However, the inventors have found that mounting the support frame 104 between the brackets 102a, 102b, as described above provides certain advantages. For example, securing the horizontal bar 108 of each wall bracket 102a, 102b to a respective one of the left frame bar 126 and the right frame bar 128 in a side-by-side configuration enables the wall rack assembly 100 to be selectively installed in either one of two configurations. FIGS. 1, 2, 9 and 11 illustrate the wall rack assembly 100 in a first assembled configuration, with the support frame 104 located at the bottom of the assembly. FIG. 12 illustrates the wall rack assembly 100 in a second (or reversed) assembled configuration, with the support frame 104 located at the top of the assembly. The wall rack assembly 100 may be installed in the second assembled configuration when optimizing space below the assembly is a priority.

The only difference between installing the wall rack assembly 100 in the first and second assembled configurations is the orientation of the wall brackets 102a, 102b. Each wall bracket 102a, 102b is rotated 180 degrees between the first and second assembled configuration. No other changes are required to the installation process.

Referring again to FIG. 2, the wall rack assembly 100 can be installed in different orders. In a first installation process, the vertical bars 106 of the respective left and right wall brackets 102a, 102b are secured to the wall before securing the support frame 104 to the respective horizontal bars 108 of left and right wall brackets 102a, 102b. It may be easier for an installer to secure the wall brackets 102a, 102b to the wall without the support frame 104 attached to the wall brackets 102a, 102b. In this way, the installer does not have to support the collective weight of each wall bracket 102a, 102b and the support frame 104 while securing the wall brackets 102a, 102b to the wall.

In another installation process, the vertical bars 106 of the respective left and right wall brackets 102a, 102b are secured to the wall after securing the support frame 104 to the respective horizontal bars 108 of left and right wall brackets 102a, 102b. It may be more convenient for an installer to secure the support frame 104 to the wall brackets 102a, 102b at ground level (i.e., before the wall brackets 102a, 102b are secured to the wall). Securing the support frame 104 to the wall brackets 102a, 102b before securing the wall brackets 102a, 102b to the wall also eliminates the need to precisely space apart the wall brackets 102a, 102b so that the support frame 104 fits between the respective horizontal bars 108.

Referring again to FIGS. 1 and 2, the wall rack assembly 100 can include one or more optional wall braces 154. In the illustrated example, the wall rack assembly 100 includes an upper wall brace 154a and lower wall brace 154b. Referring to FIGS. 2 and 6, each wall brace 154 includes a brace first end portion 156 and a brace second end portion 158 opposite the brace first end portion 156. In the illustrated example, the brace first end portion 156 is secured to the vertical bar 106 of the left wall bracket 102a and the brace second end portion 158 is secured to the vertical bar 106 of the second wall bracket 102b.

Referring still to FIGS. 2 and 6, in the illustrated example, each wall brace 154 includes a plurality of wall mounting apertures 160 spaced along the wall brace 154. In the illustrated example, a first set of the wall mounting apertures 160 is located proximate the brace first end portion 156 and a second set of the wall mounting apertures 160 is located proximate the brace second end portion 158. In installations where the vertical bar 106 of either or both the left and right wall brackets 102a, 102b does not overlie a wall stud, the wall braces 154 can be used to secure (i.e., indirectly secure) one or both of the wall brackets 102a, 102b to the wall. To secure the wall braces 154a, 154b to the wall, mechanical fasteners (e.g., screws, nails, etc.) are passed through respective mounting apertures 160 and into wall studs. For example, in installations where the vertical bar 106 of the left wall bracket 102a does not overlie a wall stud, the installer may alternatively pass a screw through one of the wall mounting apertures 160 to engage a wall stud. The same applies to the right wall bracket 102b.

Referring to FIG. 3, in the illustrated example, the vertical bar 106 of each wall bracket 102a, 102b includes a plurality of brace mounting through holes 162 spaced along the vertical bar 106. Referring to FIG. 6, each wall brace 154 includes, in the illustrated example, an elongate brace body 164 having opposed brace body edges 166, 168. The brace first and second end portions 156, 158 extend perpendicularly from a respective one of the opposed brace body edges 166, 168. In the illustrated example, each of the brace first and second end portions 156, 158 has a pair of vertically spaced apertures 170 alignable with a corresponding pair of the brace mounting through holes 162 for securing the wall brace 154 to the vertical bar 106 of a respective one of the first and second wall brackets 102a, 102b (e.g., FIG. 2). For example, a bolt can be passed through each aligned through hole 162 and aperture 170. Subsequently, a nut is threaded onto the terminal end of the bolt and tightened. In alternative examples, other forms of mechanical fasteners may be used to secure the wall brace(s) 154 to the wall brackets 102a, 102b.

Referring to FIG. 2, the wall brace(s) 154 can be secured to the wall brackets 102a, 102b at different stages in the installation process. In one example, the first and second brace end portions 156, 158 are secured to the respective vertical bars 106 of the left and right wall brackets 102a, 102b before securing the wall brackets 102a, 102b to the wall. It may be more convenient for the installer to secure the wall braces 154 to the wall brackets 102a, 102b at ground level (i.e., before the wall brackets 102a, 102b are elevated). In another example, the first and second brace end portions 156, 158 are secured to the respective vertical bar 106 of the left and right wall brackets 102a, 102b after securing the wall brace 154 to the wall. This order may be advantageous for installations in which one or more of the apertures 160 of the brace end portions 166, 168 overlie wall studs but the through holes 124 of the respective vertical bars 106 of the wall brackets 102a, 102b do not.

In yet another example, the first and second brace end portions 156, 158 are secured to the respective vertical bar 106 of the left and right wall brackets 102a, 102b after securing one of the wall brackets 102a, 102b to the wall but before securing the other of the wall brackets 102a, 102b to the wall. In this example, the installation process involves securing one of the left and right wall brackets 102a, 102b to the wall, then securing a respective one of the first and second brace end portions 156, 158 of the wall brace 154 to the wall bracket 102a, 102b secured to the wall, then securing the other of the first and second end portions 156, 158 of the wall brace 154 to the other of the wall brackets 102a, 102b, and then securing the other of the wall brackets 102a, 102b to the wall. This installation process may simplify horizontally spacing the left and right wall brackets 102a, 102b along the wall since the wall brace 154 serves as a wall bracket spacer.

Referring to FIG. 4, in the illustrated example, the support frame 104 optionally includes a frame middle bar 172 parallel to, and spaced apart from, the frame left and right bars 126, 128. The frame middle bar 172 has a middle bar front end 174 and a middle bar back end 176 opposite the middle bar front end 174. In the illustrated example, the middle bar front end 174 is welded to the frame front bar 132 and the middle bar back end 176 is welded to the frame back bar 134. The frame middle bar 172 may improve the rigidity of the support frame 104. In alternative examples, the support frame 104 does not include a frame middle bar.

Referring again to FIGS. 1 and 2, the wall rack assembly 100 may include one or more optional elongate crossmembers 178. In the illustrated example, the wall rack assembly 100 includes two elongate crossmembers 178a, 178b. Each crossmember 178 is releasably securable to the support frame 104, oriented parallel to, and spaced apart from, the frame front bar 132 and the frame back bar 134.

Referring to FIG. 7, each crossmember 178 has a crossmember first end portion 180 and a crossmember second end portion 182 opposite the crossmember first end portion 180. To secure the crossmember 178 to the support frame 104, one of the first and second crossmember end portions 180, 182 is securable to the frame middle bar 172 and the other of the first and second crossmember end portions 180, 182 is securable to a respective one of the frame left and right bars 126, 128 (e.g., FIG. 2). Any suitable type of mechanical fastener can be used to secure the crossmember 178 to the support frame 104 (e.g., bolt, clamp, pin, etc.). In examples where the support frame 104 does not include a frame middle bar, each crossmember 178 may have a length long enough for connecting the crossmember first end portion 180 to the frame left bar 126 and the crossmember second end portion 182 to the frame right bar 128.

Referring to FIG. 2, in the illustrated example, the crossmember 178a is secured to the support frame 104 by securing the crossmember first end portion 180 to frame left bar 126 and securing the crossmember second end portion 182 to the frame middle bar 172. In the illustrated example, the crossmember 178b is secured to the support frame 104 by securing the crossmember first end portion 180 to the frame right bar 128 and securing the crossmember second end portion 182 to the frame middle bar 172.

Referring to FIG. 8, in the illustrated example, the frame middle bar 172 includes a rail 184 extending upwardly from a rail lower end to a rail upper end, a left flange 186 projecting leftward from a left side of the rail lower end, and a right flange 188 projecting rightward from a right side of the rail lower end. With reference to FIGS. 5 and 8, in the illustrated example, each of the frame left bar 126 and the frame right bar 128 has an upright web 138 and a flange 140 extending laterally inwardly from a lower end of the web 138.

Referring to FIG. 8, each crossmember 178a, 178b is, in the illustrated example, securable to the support frame 104 by connecting the crossmember first end portion 180 to the flange 140 of a respective one of the frame left bar 126 and the frame right bar 128 and connecting the crossmember second end portion 182 to one of the left flange 186 and the right flange 188 of the frame middle bar 172.

Referring still to FIG. 8, in the illustrated example, each crossmember 178a, 178b is securable to the support frame 104 at any one of a plurality of depth positions. Each depth position is spaced apart from the frame front bar 132 by a respective depth spacing. The depth spacing of any one of the depth positions is distinct from the depth spacings of the other depth positions. Having the ability to selectively secure each crossmember 178a, 178b to the support frame 104 at multiple depth positions allows the assembly's user to customize the spacing between the respective crossmember 178 and the frame front bar 132. For example, referring to FIG. 9, when the wall rack assembly 100 is used to store tires 214, the crossmember(s) 178 can be selectively secured at one of the depth positions according to the tire diameter. When storing tires with larger diameters, the crossmember 178 will be secured at a depth position nearer to the frame back bar 134 than it would be for storing tires with smaller diameters.

In the illustrated example, the depth positions are provided in the form of aperture pairs. Each aperture pair includes a first aperture formed in the frame middle bar 172 and a second aperture formed in a respective one of the frame left bar 126 and the frame right bar 128 at the same depth spacing as the first aperture 190, 192. Referring to FIG. 7, in the illustrated example, each of the crossmember first and second end portions 180, 182 include frame mounting apertures 198 for securing the crossmember 178 to the desired aperture pair of the support frame 104 (e.g., using screws or other suitable fasteners).

Referring back to FIG. 8, the left flange 186 of the frame middle bar 172 includes a plurality of left flange apertures 190 spaced apart lengthwise along the left flange 186. Similarly, the right flange 188 of the frame middle bar 172 includes a plurality of right flange apertures 192 spaced apart lengthwise along the right flange 188. The flange 140 of the frame left bar 126 includes a plurality of left bar apertures 194 spaced apart lengthwise along the respective flange 140. Similarly, the flange 140 of the frame right bar 128 includes a plurality of right bar apertures 196 spaced apart lengthwise along the respective flange 140. Each aperture pair includes either i) one of the left flange apertures 190 and a corresponding one of the left bar apertures 194 or ii) one of the right flange apertures 192 and a corresponding one of the right bar apertures 196.

Referring to FIG. 10, the support frame 104 defines a support frame opening 200 bounded by the frame left and right bars 126, 128 and the frame front and back bars 132, 134. The wall rack assembly 100 includes one or more optional decks 202 for covering at least a portion of the support frame opening 200.

In the illustrated examples, the wall rack assembly 100 includes a first deck 202a for covering a left portion of the support frame opening 200 between the frame left bar 126 and the frame middle bar 172, and a second deck 202b for covering a right portion of the support frame opening 200 between the frame right bar 128 and the frame middle bar 172. In the illustrated example, the decks 202a, 202b comprise a wire grid. In alternative examples, one or more of the decks 202a, 202b may be formed of sheet metal.

Referring still to FIG. 10, in the illustrated example, each deck 202 includes a planar portion 204, a front retainment ledge 206 projecting downwardly from a front edge of the planar portion 204, and a back retainment ledge 208 extending downwardly from a back edge of the planar portion 204. Referring to FIG. 11, when the decks 202a, 202b are positioned on the support frame 104, the front retainment ledge 206 of each deck overlies a forward-facing surface of the frame front bar 132 and the back retainment ledge 208 (FIG. 10) of each deck overlies a rearward-facing surface of the frame back bar 134. Optionally, each deck 202a, 202b can be further secured to the support frame 104 with mechanical fasteners (e.g., U-bolts).

In the illustrated example, respective upper surfaces of each of the frame front bar 132, the frame back bar 134, the frame left bar 126, the frame right bar 128, and the frame middle bar 172 lie in a common plane (i.e. have the same elevation). In the illustrated example, each crossmember 178a, 178b has a respective crossmember upper surface 216 that lies in the common plane when the respective crossmember 178a, 178b is secured to the support frame 104. With the upper surfaces 216 lying in the common plane, each crossmember 178a, 178b is able to help support the respective deck 202a, 202b from below. This additional support may limit deck sag when the respective deck 202a, 202b is under load.

Referring now to FIG. 13, a kit 300 for a wall rack includes the prefabricated wall brackets 102a, 102b and the prefabricated rectangular support frame 104. Optionally, the kit 300 further includes at least one wall brace 154, at least one crossmember 178 and at least one deck 202. In the illustrated example, the kit 300 includes two wall braces 154a, 154b, two crossmembers 178a, 178b and two decks 202a, 202b.

What has been described above is intended to be illustrative of examples of the teaching disclosed herein, without limiting the scope of patent claims granted herefrom. The scope of such claims should be given the broadest interpretation consistent with the description as a whole.