Reinforcement system for an extra-wide display shelf
A system and method of reinforcement of an extra-wide display shelf for a gravity-fed display system. The shelf includes a front rail, a rear rail and two side rails disposed between the front rail and the rear rail, a plurality of cross-rails extending from the front rail to the rear rail parallel to and between the side rails, and a plurality of horizontal rails disposed under the plurality of cross-rails. The reinforcement system includes a plurality of support rails disposed under and perpendicular to the plurality of horizontal rails, and a plurality of reinforcement rails disposed perpendicular to and under the plurality of support rails. The reinforcement system puts the surface of the shelf in tension or otherwise bends a center region of the surface of the shelf upward when unloaded (or when free of product) to offset downward deflection due to weight of product to be displayed.
1. A gravity-fed display system comprising:
a rack having front support legs and rear support legs disposed opposite the front support legs; and
at least one display shelf disposed within the rack, the display shelf comprising:
a front rail, a rear rail disposed opposite the front rail, and two side rails disposed between the front rail and the rear rail;
a plurality of cross-rails, wherein each cross-rail extends from the front rail to the rear rail parallel to and between the side rails, along the length of the front and rear rails;
a plurality of horizontal rails disposed under the plurality of cross-rails, wherein each horizontal rail extends from one side rail to the other side rail parallel to and between the front and rear rails, the plurality of cross-rails and the plurality of horizontal rails forming a surface of the shelf, the surface of the shelf having an underside; and
a reinforcement system disposed on the underside of the shelf, the reinforcement system including:
a plurality of support rails disposed perpendicular to and under the plurality of horizontal rails, wherein each support rail is welded to at least one horizontal rail; and
a plurality of reinforcement rails disposed perpendicular to and under the plurality of support rails, wherein each reinforcement rail includes a first end, a second end disposed opposite the first end, and a middle section disposed between the first and second ends, and wherein the first and second ends of the reinforcement rails are bent in one direction and welded to one horizontal rail of the plurality of horizontal rails and the middle sections of the reinforcement rails are welded to at least one support rail,
the reinforcement system thereby bending the surface of the shelf such that a center region of the shelf bows in an upward direction when unloaded to offset downward deflection of the center region of the shelf due to weight of product to be displayed thereon.
2. The gravity-fed display system of claim 1 , wherein the plurality of support rails of the display shelf further includes a first support rail disposed at an approximate center of the surface of the shelf, a second support rail and a third support rail, wherein each of the second and third support rails are spaced the same distance from the first support rail on either side of the same.
3. The gravity-fed display system of claim 1 , wherein the plurality of horizontal rails includes six horizontal rails and the plurality of reinforcement rails includes six reinforcement rails.
4. The gravity-fed display system of claim 1 , wherein the number of horizontal rails is equal to the number of reinforcement rails.
5. The gravity-fed display system of claim 1 , wherein the front and rear support legs each include holes to enable one or more display shelves to be placed at any desired height and angle of incline along the legs.