Shelving brace

Abstract

A rectangular shelf is supported along its sides by opposing deck beams and supported on its ends by opposing end frame members, all joined to corner posts. A hook on each opposing end of a cross-brace engages a different latch affixed to each deck beam to keep the deck beams from splaying under heavy load. The latches are formed from a threaded nut or a washer having a flat side that is affixed to the deck beam by heat or an adhesive.

What is claimed is: 
     
         1 . A deck beam and cross-brace for use with a support frame for a shelf in a shelving assembly, said shelf assembly including a pair of rear posts extending upward and an opposed pair of front posts extending upward with elongated front and rear deck beams extending between and connected to respective pairs of rear posts and front posts in the same plane and parallel to each other to define a support for a shelf, each of the deck beams having an upper side and a lower side, the deck beam and cross-brace comprising:
 a first deck beam having a first shelf support surface extending along a length of the first deck beam adjacent an upper side of the first deck beam, and a threaded nut or a washer each having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of first deck beam to form a first latch located adjacent the lower side of the first deck beam, the nut or washer being orientated relative to the first deck beam so an opening through the nut or washer faces upward during use;   a second deck beam having a second shelf support surface extending along a length of the second deck beam adjacent an upper side of the second deck beam, and a threaded nut or a washer having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of second deck beam to form a second latch located adjacent the lower side of the first deck beam, the nut or washer being orientated relative to the second deck beam so an opening through the nut or washer faces upward during use, the first and second latches located at corresponding locations on their respective deck beams so the first and second latches are directly opposite each other during use;   a cross-brace having an elongated body with two opposing ends, each end having a hook extending in the same direction during use, each hook sized to fit through the opening in one of the first or second latches during use, the cross-brace having a length selected so the each hook can pass through the upward facing opening of a different latch during use when the latches are directly opposite each other, and the hooks being configured to pass through the openings during use.   
     
     
         2 . The deck beam and cross-brace of  claim 1 , wherein melted metal affixes the latch to the deck beam. 
     
     
         3 . The deck beam and cross-brace of  claim 2 , wherein at least one latch is a threaded nut. 
     
     
         4 . The deck beam and cross-brace of  claim 2 , wherein at least one latch is a threaded nut and the opening is elongated with a long axis perpendicular to the deck beam at the location of the latch. 
     
     
         5 . The deck beam and cross-brace of  claim 2 , wherein at least one latch is a square nut. 
     
     
         6 . The deck beam and cross-brace of  claim 2 , wherein at least one latch is a hexagonal nut. 
     
     
         7 . The deck beam and cross-brace of  claim 2 , wherein the first latch is generally parallel to the first shelf support and the second latch is generally parallel to the second shelf support. 
     
     
         8 . The deck beam and cross-brace of  claim 2 , wherein the first latch is inclined at an angle of about 30 degrees or less from an axis perpendicular to the first shelf support. 
     
     
         9 . The deck beam and cross-brace of  claim 2 , wherein the cross-brace is a rod with a circular cross-section. 
     
     
         10 . The deck beam and cross-brace of  claim 2 , wherein the cross-brace is one of a braided metal or chain. 
     
     
         11 . The deck beam and cross-brace of  claim 2 , wherein the cross-brace has one end smaller in cross-section than the other end. 
     
     
         12 . The deck beam and cross-brace of  claim 1 , wherein an adhesive affixes at least one of the first and second latches to the deck beam and said one of the first and second latches comprises a threaded nut. 
     
     
         13 . The deck beam and cross-brace of  claim 1 , wherein the first and second latches are located at about the center of a length of the respective deck beams. 
     
     
         14 . The deck beam and cross-brace of  claim 2 , wherein at least one of the first and second latches is a washer with a flat side. 
     
     
         15 . The deck beam and cross-brace of  claim 14 , wherein the opening in at least one of the first and second latches is elongated with a long axis perpendicular to the deck beam at the location of the at least one latch. 
     
     
         16 . The cross-brace and latch of  claim 14 , wherein the first latch is generally parallel to the first shelf support and the second latch is generally parallel to the second shelf support. 
     
     
         17 . The deck beam and cross-brace of  claim 14 , wherein the first latch is inclined at an angle of about 30° or less from an axis perpendicular to the first shelf support. 
     
     
         18 . The deck beam and cross-brace of  claim 14 , wherein the cross-brace is a rod with a circular cross-section. 
     
     
         19 . The deck beam and cross-brace of  claim 14 , wherein the cross-brace is one of a braided metal or chain. 
     
     
         20 . The deck beam and cross-brace of  claim 14 , wherein the cross-brace has one end smaller in cross-section than the other end. 
     
     
         21 . The deck beam and cross-brace of  claim 1 , wherein the first and second latches are located at about the center of a length of the respective deck beams. 
     
     
         22 . A kit for a shelving assembly having a pair of rear posts configured to extend upward during use and a pair of front posts configured to extend upward during use, at least one pair of elongated front and rear deck beams configured to extend between and connected to respective pairs of rear posts and front posts in the same plane and parallel to each other to define a support for a shelf during use, the kit comprising:
 a plurality of first deck beams having a first shelf support surface extending along a length of the respective first deck beam adjacent an upper side of the respective first deck beam, the plurality of first deck beam having a threaded nut or a washer each having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of respective first deck beam to form a first latch located adjacent the lower side of the respective first deck beam, the nut or washer being orientated relative to the respective first deck beam so an opening through the nut or washer faces upward during use;   a plurality of second deck beams having a second shelf support surface extending along a length of the respective second deck beam adjacent an upper side of the respective second deck beam, and a threaded nut or a washer having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of respective second deck beam to form a second latch located adjacent the lower side of the respective second deck beam, the nut or washer being orientated relative to the respective second deck beam so an opening through the nut or washer faces upward during use, the first and second latches located at corresponding locations on their respective deck beams so the first and second latches are directly opposite each other during use;   a plurality of cross-braces each having an elongated body with two opposing ends, each end having a hook extending in the same direction during use, each hook sized to fit through the opening in one of the first or second, directly opposing latches during use, the cross-braces each having a length selected so the each hook can pass through the upward facing opening of a different latch during use when the latches are directly opposite each other, and the hooks being configured to pass through the openings during use.   
     
     
         23 . A shelving unit having a pair of rear posts extending upward and a pair of front posts extending upward with two pairs of elongated front and rear deck beams extending between and releasably connected to respective pairs of rear posts and front posts in the same plane and parallel to each other to define a support for a shelf during use, the shelf comprising:
 a first shelf having two opposing first deck beams each having a first shelf support surface extending along a length of the respective first deck beam adjacent an upper side of the respective first deck beam, each of first deck beams having a threaded nut or a washer each with a solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of each respective first deck beam to form a first latch located adjacent the lower side of the respective first deck beam, the first latches being orientated relative to the respective first deck beam so an opening through the nut or washer faces upward, the first latches being directly opposite each other;   a plurality of second deck beams having a second shelf support surface extending along a length of the respective second deck beam adjacent an upper side of the respective second deck beam, and a threaded nut or a washer having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of respective second deck beam to form a second latch located adjacent the lower side of the respective second deck beam, the nut or washer being orientated relative to the respective second deck beam so an opening through the nut or washer faces upward, the first and second latches located at corresponding locations on their respective deck beams so the first and second latches are directly opposite each other;   a first cross-brace having an elongated body with two opposing ends, each end having a hook extending in the same direction, each hook fitting through the opening in a different one of the first latches to help the first deck beams resist splaying under a heavy load;   a second shelf and second cross-brace constructed as the first shelf and first cross-brace, but spaced apart therefrom.   
     
     
         24 . The shelving unit of  claim 23 , wherein the latches comprise threaded fasteners affixed to the deck beams by solidified metal. 
     
     
         25 . A method of making a latch for a deck beam for use with a shelving unit having opposing deck beams each connected to different pairs of posts to form a support for a rectangular shelf, where the latch has an opening extending therethrough which is configured to receive a hook on the end of a cross-brace, the method comprising:
 placing one of a washer with a flat side or a threaded nut having a flat side against a side of a deck beam, the deck beam having a shelf support extending along an upper side of the deck beam and configured to support a side of a shelf during use, the deck beam having one of a connector or a recess at opposing distal ends of the deck beam to releasably connect the deck beam to a post during use; and   positioning the one of the washer or threaded nut adjacent a lower side of the deck beam with a face of the one of the washer or threaded nut facing toward the shelf support; and   applying heat or an adhesive to the one of the washer or threaded nut to affix the one of the washer or threaded nut to the deck beam and form a latch for a cross-brace.   
     
     
         26 . The method of claim  28 , wherein the positioning step positions a threaded nut generally parallel to the shelf support and the applying step uses heat to melt at least one of the deck beam and the threaded nut. 
     
     
         27 . The method of claim  28 , wherein the positioning step positions a washer generally parallel to the shelf support and the applying step uses heat to melt at least one of the deck beam and the threaded nut.