U.S. patent application number 17/824289 was filed with the patent office on 2022-09-15 for storage support member with connection portion.
The applicant listed for this patent is FRAZIER INDUSTRIAL COMPANY. Invention is credited to Aaron IELLIMO, Domenick IELLIMO.
Application Number | 20220289476 17/824289 |
Document ID | / |
Family ID | 1000006364653 |
Filed Date | 2022-09-15 |
United States Patent
Application |
20220289476 |
Kind Code |
A1 |
IELLIMO; Domenick ; et
al. |
September 15, 2022 |
STORAGE SUPPORT MEMBER WITH CONNECTION PORTION
Abstract
Warehouse support structures capable of supporting 3000 pounds
or more are fastened to the inside surface of a horizontal support
beam attached to a vertical column. A structural support member
spans the horizontal support beams and support a platform, such as
a mesh platform is supported thereon. The support member can be an
inverted formed U or an angle beam. The angle beam should have an
attachment bracket secured to each end, at a height to permit the
platform to have the same height as the horizontal beam. The mesh
platform should nest in the inside surface of the horizontal beam,
between the support member and the beam. The construction presents
a smooth, easy to assemble, snag free construction.
Inventors: |
IELLIMO; Domenick; (Forked
River, NJ) ; IELLIMO; Aaron; (Califon, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FRAZIER INDUSTRIAL COMPANY |
Long Valley |
NJ |
US |
|
|
Family ID: |
1000006364653 |
Appl. No.: |
17/824289 |
Filed: |
May 25, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16943333 |
Jul 30, 2020 |
11390460 |
|
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17824289 |
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62882115 |
Aug 2, 2019 |
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62896663 |
Sep 6, 2019 |
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62983967 |
Mar 2, 2020 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65G 1/04 20130101; A47B
96/1441 20130101; A47B 96/021 20130101 |
International
Class: |
B65G 1/04 20060101
B65G001/04; A47B 96/14 20060101 A47B096/14; A47B 96/02 20060101
A47B096/02 |
Claims
1. A storage system, comprising: a first and a second horizontal
support beam, each having a concave inner surface facing the
concave inner surface of the other support beam; a plurality of
support members coupled to the support beams, perpendicular to the
support beams and extending from the first support beam to the
second support beam, the support members having a central section
with a load bearing upward facing surface and first and second
ends, and first and second connection portions extending,
respectively, from each end of the central section, the first and
second connection portions adapted to be secured to the concave
inner surface of the first and second support beams; a deck
structure with an upward facing storage surface on the load bearing
surface, the deck structure having a first edge along the first
support beam and a second edge along the second support beam, the
first and second edges extending downward with respect to the
storage surface; the first and second edges of the deck structure
nested along the concave inner surface of the first and second
support beams, respectively, and the first and second connection
portions nested along the first and second edges, respectively, and
the first and second connection portions are secured to the
respective first and second support beams with the respective first
and second edges therebetween.
2. The storage system of claim 1, wherein a bolt extends through
the first support beam, the first edge and the connection portion,
in that order, with the head of the bolt outside the support
beam.
3. The storage system of claim 1, wherein the deck is formed of a
plurality of lower rods perpendicular to the support members and a
plurality of upper rods, on the lower rods, perpendicular to the
lower rods, the upper rods extending downward at the first and
second edges.
4. The storage system of claim 1, wherein at least one of the
support members is cold formed from a single piece of metal and the
central section has a U-shaped, curved, dome-like cross section
with an upwardly pointing apex.
5. The storage system of claim 4, wherein the first and second
connection portions of the at least one support member includes a
respective first and second flat portion with at least one bolt
receiving hole therethrough, the flat portion extending downward
from the respective first and second ends of the central
section.
6. The storage system of claim 1, wherein at least one of the
support members has an L-shaped cross section, with a flat upper
wall and a vertical wall extending downward from a vertex with the
upper wall.
7. The storage system of claim 6, wherein the connection portion
comprises an L-shaped metal piece joined to the central
portion.
8. The storage system of claim 6, wherein the connection portion
comprises an L-shaped metal piece welded to the vertical wall.
9. The storage system of claim 1, wherein the support beams are
C-beams having an inner facing concave surface defined by a top
flange, a vertical wall and a bottom flange, wherein the first and
second edges of the deck structure conform to the shape of a
surface of the top flange and vertical wall of the C-beam.
10. The storage system of claim 1, wherein the deck structure has a
width in the direction from the first to the second support beam of
at least 40 inches.
11. The storage system of claim 1, wherein the central section has
a uniform cross section.
12. The storage system of claim 1, wherein the connection portion
includes at least 3 bolt receiving holes, each a different distance
below the load bearing surface.
13. The storage system of claim 1, comprising at least 3 similar
support members.
14. The storage system of claim 3, wherein rods are formed of
steel.
15. The storage system of claim 4, wherein the support members are
formed from steel.
16. The storage system of claim 6, wherein the support members are
formed from steel.
17. A storage system, comprising: a deck structure with an upward
facing storage surface, the deck structure having a first side and
a second side opposite and parallel to the first side, a first edge
extending downward from the first side and a second edge extending
downward from the second side; a plurality of support members,
perpendicular to the first and second sides, the support members
having a central section with a load bearing upward facing surface
supporting the deck structure, and first and second ends, with
first and second connection portions extending, respectively, from
each end, the first and second connection portions adapted to be
secured to the concave inner surface of a horizontal C-beam; the
first and second connection portions nested along the first and
second edges, respectively, and the first and second connection
portions are securable to the connection portions.
18. The storage system of claim 17, wherein at least one of the
support members is cold formed from a single piece of metal and the
central section has a U-shaped, curved, dome-like cross section
with an upwardly pointing apex.
19. The storage system of claim 17, wherein at least one of the
support beams has an L-shaped cross section, with a flat upper wall
and a vertical wall extending downward from a vertex with the upper
wall.
20. A storage system, comprising: a structural support member
having a central section more than about 40 inches long, having a
first end and a second end; an attachment portion secured to the
first and second ends, the attachment portion having a flat
attachment surface perpendicular to the axis of the central portion
and adapted to be attached to a horizontal support beam; the
central section having an L-shaped cross section, with a top wall
extending horizontally from a vertex and a side wall extending
vertically from the vertex at a right angle to the top wall.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority as a continuation of
application Ser. No. 16/943,333, filed Jul. 30, 2020, and the
benefit of provisional applications 62/882,115, filed Aug. 2, 2019,
62/896,663, filed Sep. 6, 2019 and 62/983,967, filed Mar. 2,
2020.
BACKGROUND OF THE INVENTION
[0002] Storage systems are commonly used in warehouses, department
stores, and storage facilities to store products thereon. Storage
systems containing a plurality of storage racks may hold and
support large amounts and often heavy materials. Often, the goods
are stored on pallets, which can weigh 3000 pounds or more when
fully loaded.
[0003] Storage rack systems often employ a number of vertical
columns that are sturdily positioned on a base or floor. A
plurality of horizontal supporting beams are often fastened to the
vertical columns, such as with bolts or rivets. Typically, a number
of horizontal support members are positioned directly on and
substantially perpendicular to the horizontal supporting beams to
provide a supporting surface for shelves, pallets, mesh surfaces,
etc.
[0004] If the support members are not fastened to the horizontal
beams, they can become displaced as items are loaded over the
support members or as a storage surface is placed on the support
members. Attaching the support members to the horizontal beams can
be complicated and can result in structures extending past the edge
of the beams. This can interfere with the loading and unloading
processes, or snare objects passing by, thereby hindering the
stability and reliability of the storage rack.
[0005] Accordingly, it is desirable to provide an improved storage
surface and method of securing the surface to horizontal beams that
overcomes drawbacks of existing systems and methods.
SUMMARY OF THE INVENTION
[0006] The invention relates to a rack support system. The rack can
be formed with vertical columns with horizontal support beams
thereon. Support members can lay across the beams and support a
deck as a storage surface for pallets, cartons and the like.
[0007] One preferred support member in accordance with the
invention can be cold formed. Formed support members in accordance
with the invention are constructed to be structurally steady, easy
to manufacture and do not interfere with the operations of loading
and unloading processes is disclosed herein. The support member can
support a storage platform and stay in place as the platform and
items are placed thereon.
[0008] In one embodiment of the invention, the formed support
member comprises a downwardly facing U-shaped body, having a dome
shaped cross section and an upwardly pointing apex to serve as a
load bearing surface. The U-shaped body has a central section,
preferably uniform, that is elongated in an axial direction. The
member can be formed by cold or hot working metals such as steel or
aluminum, such as by pressing or rolling. The member is preferably
formed from a single piece of material. Each end of the support
member forms a connection flap and extends from the U-shaped body
in a downward direction perpendicular to the longitudinal axis of
the support member. The transition from the central section should
be curved and non-angular. The connection flap can be formed by
cold or hot working, such as rolling, pressing or bending. It
preferably has a generally pentagon-like shape and at least one
bolt receiving hole therethrough.
[0009] The connection flap should have a slightly curved shape at
its top, where it transitions from the central section, to
substantially conform to the internal concavity of a horizontal
I-beam or C-beam, as the horizontal support beam to which it is
attached. A first engaging end of the connection flap should have a
substantially flat portion to nest against the flat vertical wall
of the horizontal beam and having at least one opening, such as a
bolt receiving hole. The engaging end can include multiple holes to
correspond to multiple sizes of horizontal beams, such as
connection holes in the center of 3 inch, 3.5 inch or 4 inch high
horizontal beams. The support member can also include a second end
extending from the central section in an opposite direction along
the same longitudinal axis as the first end. The second end can
have a mirror image of the first end as a curved shape to
substantially conform to the internal concavity of another C-beam
or I-beam horizontal supporting beam. The second end can also have
a second engaging end that is substantially flat for engaging the
vertical wall of the horizontal support beam and curved at its top
to conform to the upper concave portion of the horizontal C-beam or
I-beam. The second engaging end can have at least one hole to
overlap a hole formed through the horizontal beam. The second
engaging end can have multiple holes for use with multiple sized
horizontal beams. These inverted U-shaped support beams are best
suited for lengths of about 2-4, more preferably 2.5-3.5 feet.
[0010] A storage system in accordance with another embodiment of
the invention comprises the formed support member disclosed herein
having a storage surface, such as a deck or grating thereon. The
deck/grating can comprise a plurality of evenly spaced parallel
rods or thick wires that are substantially parallel to the formed
support members and a plurality of evenly spaced perpendicular rods
or thick wires that are substantially perpendicular to the formed
support members. The perpendicular rods/wires should be positioned
underneath the parallel rods, so that weight on the parallel rods
is directly transmitted to the perpendicular rods, which rest
directly across the support members. The system can include 2, 3, 4
or more support members depending on the width of the storage
surface. The intersections of the parallel rods and the
perpendicular rods may be welded, woven or joined by any other
conventional methods.
[0011] Both ends of a parallel rod should be bent downward to form
an upper curved shape and preferably a lower flat shape and
substantially conform to the internal concavity of the respective
horizontal supporting beam and the curvature of the end of the
formed support member, so that the end of the parallel rod fits
snugly between the horizontal supporting beam and the formed
support member. A bolt can extend through a bolt receiving hole in
a vertical wall of the horizontal beam, through the space between
rods at the end of the deck/grating, then through the hole in the
engaging end of the formed support member. Therefore, no part of
the support structure, including the deck, other than the head of a
bolt, needs to extend past the outer plane of the horizontal
beam.
[0012] A deck in accordance with an embodiment of the invention can
be configured such that the upper surface formed by the parallel
rods is substantially in about the same plane as an upper surface
of the horizontal support member, and preferably the upper surface
of the horizontal support beams. This facilitates loading goods,
pallets and the like onto the deck without obstruction. The support
members can be slightly deflected at the transition to the
connection flap to lower the load bearing surface at the top of the
support member by the thickness of the deck/grating, such that the
storage surface is on the same plane as the horizontal beams.
[0013] The perpendicular rods should be substantially in contact
with the supporting load bearing surface of the formed support
member so that the formed support member provides sufficient
support to the deck thereon.
[0014] The deck can also comprise a set of at least two fastening
rods affixed on both ends of the parallel rods. These ends are bent
downward, substantially perpendicular to the storage surface. The
fastening rods should be substantially parallel to the
perpendicular rods and substantially perpendicular to the parallel
rods and the formed support member. The fastening rods should be
spaced to fit bolts of various sizes between the openings (bolt
receiving openings) between the various rods.
[0015] The formed support member may comprise one, two, three or
more holes through the first engaging end and the second engaging
end. The horizontal support beams are typically formed with bolt
receiving holes therethrough, typically through the vertical wall,
midway between the top and bottom edge/flange. The hole(s) through
the first or second engaging end of the support member should be
positioned to accommodate differently sized horizontal support
beams and decks, so that once a deck is positioned above one or
more formed support members, at least one hole through the first or
second engaging ends of the formed support member is aligned with a
space between two adjacent fastening rods and a hole through the
horizontal support beam, for insertion of a bolt to extend through
the beam, past the rods and through the engaging end.
[0016] Deck/storage surface structures in accordance with the
invention can comprise a set of three, four or more fastening rods
on both ends of the parallel rods, sized and positioned to
accommodate differently sized horizontal support beams and formed
support members, so that once a deck is positioned above one or
more formed support members, at least one space between two
adjacent fastening rods is aligned with a hole through the
horizontal support beam, between the rods and through the engaging
end of the formed support member.
[0017] An angle shaped support member, generally rolled, in
accordance with another embodiment of the invention, has a function
similar to the inverted U-shaped support member, but can more
easily be constructed to have greater strength, to span greater
distances between horizontal support beams. This can more
conveniently provide deck surfaces of greater area to accommodate
larger areas of goods. For example, angle shaped support members
can be used to span beam gaps over 4, 5, and even 6 feet and
larger.
[0018] An angle shaped support member has a generally "L"-shaped
cross section. The angle shaped support member can be formed with a
top wall, providing a load bearing surface, aligned with a
horizontal plane and a vertical wall extending down and
perpendicular to the horizontal plane, with a substantially right
angle therebetween.
[0019] The top wall and vertical wall can be symmetric or can have
differing lengths from the vertex in a direction perpendicular to
the longitudinal axis of the angle shaped support member. In one
embodiment of the invention, the top wall has a width of about 1.5
to 3, preferably about 2 inches perpendicular to the longitudinal
axis and the vertical wall has a height of 1.5 to 4 inches,
preferably 2, 2.5 or 3 inches perpendicular to the longitudinal
axis.
[0020] In one embodiment of the invention, an engagement end is
formed at both ends of the angle shaped support member by slicing
the vertex at the first and second ends of the angle shaped support
member. The top surface is then bent downward. The endmost portion
of the top surface is bent perpendicular to the longitudinal axis,
to present a flat surface facing the horizontal support beam. One
or more bolt receiving holes can be formed through the flat surface
at the engagement end of the angle shaped support member to overlap
a bolt receiving hole through the horizontal support beam. The
portion of the vertical surface extending past the slice in the
vertex can be cut or bent out of the way.
[0021] In another embodiment of the invention, an angle bracket
having an attachment arm and an engagement arm at a right angle to
the attachment arm is attached to both ends of the angle shaped
support member. In one embodiment of the invention, the attachment
arm is welded to the outside surface of the vertical wall and the
engagement arm extends across the front end of the support member.
The engagement arm includes 1, 2, 3, or 4 or more bolt receiving or
other holes therethrough and can nest flat, against the vertical
wall of the horizontal beam, with the at least one hole overlapping
a hole formed through the horizontal beam, for receiving a
connection bolt.
[0022] Decks/support surfaces in accordance with the invention can
be constructed to support more than 3000 pounds. The decks can have
a width of about 40-50, preferably 43-47 inches, most preferably
about 455/8 inches and a depth of 37-47 inches, preferably 41-45
inches, most preferably about 433/4 inches. Angle shaped support
members can have a top wall of about 1-3 inches, preferably
1.75-2.5 inches, most preferably about 2 inches and a vertical wall
about 1.5-3.5, preferably 1.75-3.25 inches, most preferably about 2
or 3 inches. They can have lengths over 30, 40 and even 50 inches.
Preferred lengths are 36-48 inches for many applications, although
lengths of 4 to 5 feet are acceptable.
[0023] Angle brackets in accordance with the invention can have a
width of about 2.5-3.5, preferably 3 inches, and an attachment
surface to the support member of about 2.5-3.5, preferably 3 inches
and a height of about 1.75-2.25, preferably 2 inches. The top of
the angle bracket should be positioned lower than the top surface
of the angle shaped support member, so that it nests under the
upper flange of the horizontal support beam. In addition, room
should be provided for the rods of the deck. Therefore, the angle
bracket should be positioned low enough so that the upper surface
of the support member, with deck thereon, is level with the upper
surface of the horizontal support beam, to prevent goods from
catching during loading or unloading.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 illustrates a first embodiment of a formed support
member of the storage rack in accordance with aspects of the
present disclosure;
[0025] FIG. 2 illustrates a second embodiment of a formed support
member of the storage rack in accordance with aspects of the
present disclosure, wherein FIG. 2A is a top view, FIG. 2B is a
front view and FIG. 2C is a side view;
[0026] FIG. 3 illustrates a third embodiment of a formed support
member of the storage rack in accordance with aspects of the
present disclosure, wherein FIG. 3A is a top view, FIG. 3B is a
side view and FIG. 3C is an end view;
[0027] FIG. 4A illustrates a top view of a deck of a storage rack
in accordance with aspects of the present disclosure; FIGS. 4B and
4C illustrate side views of the deck of the storage rack in
accordance with aspects of the present disclosure; and FIG. 4D
illustrates a front end view of the deck of the storage rack in
accordance with aspects of the present disclosure;
[0028] FIG. 5A illustrates a top plan view of a system comprising a
deck of a storage rack positioned on three formed support members
in accordance with aspects of the present disclosure; FIG. 5B
illustrates a cross sectional view of the deck and one of the three
formed support members in accordance with aspects of the present
disclosure; and FIG. 5C illustrates a front end view of the deck
positioned on three formed support members in accordance with
aspects of the present disclosure;
[0029] FIGS. 6A and 6B illustrate front end views of a second
embodiment of a system comprising a deck of a storage rack
positioned on three formed support members in accordance with
aspects of the present disclosure;
[0030] FIGS. 7A and 7B illustrate front end views of a third
embodiment of a system comprising a deck of a storage rack
positioned on three formed support members in accordance with
aspects of the present disclosure;
[0031] FIG. 8 is a perspective view of a support member in
accordance with a preferred embodiment of the invention;
[0032] FIG. 9 is a top view of the support member of FIG. 8;
[0033] FIG. 10 is a side view of the support member of FIG. 8;
[0034] FIG. 11 is a front end view of the support member of FIG.
8;
[0035] FIG. 12 is a perspective view of a support member in
accordance with another embodiment of the invention;
[0036] FIG. 13 is a side view of a support member, bolted to a
horizontal support beam and having a deck structure resting
thereon, in accordance with an embodiment of the invention;
[0037] FIG. 14 is an enlarged partial side view of an end portion
of the structure of FIG. 13;
[0038] FIG. 15 is a perspective partial cut away view of multiple
deck structures supported by multiple support members supporting
multiple deck structures, attached to horizontal support beams and
supported by vertical columns, in accordance with an embodiment of
the invention;
[0039] FIG. 16 is an enlarged partial cut away perspective view of
the structures depicted in FIG. 15; and
[0040] FIG. 17 is a partial cut away side view of the structure of
FIG. 15.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] The present disclosure may be understood more readily by
reference to the following detailed description of the disclosure
taken in connection with the accompanying figures, which form a
part of this disclosure. It is to be understood that this
disclosure is not limited to the specific devices, methods,
conditions or parameters described and/or shown herein, and that
the terminology used herein is for the purpose of describing
particular embodiments by way of example only and is not intended
to be limiting of the claimed disclosure.
[0042] Also, as used in the specification and including the
appended claims, the singular forms "a," "an," and "the" include
the plural, and reference to a particular numerical value includes
at least that particular value, unless the context clearly dictates
otherwise. Ranges may be expressed herein as from "about" or
"approximately" one particular value and/or to "about" or
"approximately" another particular value. When such a range is
expressed, another embodiment includes from the one particular
value and/or to the other particular value. Similarly, when values
are expressed as approximations, by use of the antecedent "about,"
it will be understood that the particular value forms another
embodiment.
[0043] Warehouse support structures are commonly used to support
heavy loads of 3000 pounds and more. Some are fastened to the
inside surface of a horizontal support beam attached to a vertical
column. A structural support member in accordance with the
invention can span the horizontal support beams and support a
platform, such as a mesh platform. The support member can be an
inverted formed U or an angle beam. The angle beam should have an
attachment bracket secured to each end, at a height to permit the
platform to have the same height as the horizontal beam. The mesh
platform should nest in the inside surface of the horizontal beam,
between the support member and the beam.
[0044] The support beam can have a central section having a first
end and a second end and an attachment portion extending past and
downward from the first or second end. The central section can have
a L-shaped cross section, with a top wall extending horizontally
from a vertex and a side wall extending vertically from the vertex
at a right angle to the top wall. The vertical wall can have a
length terminating at the first or second end of the central
portion and the attachment portion can comprise an attachment
portion of the top wall, at least at the first end of the central
section.
[0045] In one embodiment of the invention, the top wall can extend
past the length of the vertical wall and deflect downward from a
plane of the top wall at a first bend and deflects further downward
at a second bend, such that after the second bend, the portion of
the top wall extending past the first end of the central section
extends vertically downward at a right angle to the top wall. At
least one bolt receiving holes should be is formed through the
attachment portion. A mesh platform can rest on the top wall, the
platform having a main portion parallel to the plane of the top
wall and edges that curl down from the plane of the top wall and
conform to the attachment portion.
[0046] The support member can be secured to a horizontal C-beam
having a concave surface defined by a top flange, a vertical wall
and a bottom flange, wherein the connection portion conforms to the
shape of a surface of the top flange and vertical wall of the
C-beam faces the connection portion. A bolt can extend, in
sequence, through the C-beam, the edge of the mesh platform and the
connection portion.
[0047] Reference will now be made in detail to the exemplary
embodiments of the present disclosure, which are illustrated in the
accompanying drawings.
[0048] FIG. 1 illustrates a first embodiment of a formed support
member of a storage rack in accordance with aspects of the present
disclosure. The formed support member 100 comprises a downwardly
facing U-shaped body 110 elongated in an axial direction to form a
supporting load bearing surface 101. A first end 102 extended from
a central section of the U-shaped body in one direction along the
axis and has a curved portion to substantially conform to the
internal concavity of a horizontal supporting beam and a
substantially flat first engaging end 103 with at least one hole
104. On the opposite direction of the first end 102, a second end
105 extends from the central section of the U-shaped body in an
opposite direction along the axis and also has a curved portion to
substantially conform to the internal concavity of another
horizontal supporting beam and a substantially flat second engaging
end 106 being with at least one hole 107.
[0049] The length l of the formed support member 100 is defined by
the shortest distance between the first engaging end 103 and second
engaging end 106. The length l is in the range of from 20 to 44
inches, preferably, from 30 to 40 inches. The length l can be
shorter or longer than the specifically recited ranges depending on
the dimensions of the storage rack.
[0050] The width w of the first engaging end 103 and the width w'
of the second engaging end 106 are preferably in the range of from
3 to 5 inches. The width w and w' can be shorter or longer than the
specifically recited ranges depending on the dimensions of the
storage rack, the weight of the load, the material of the formed
support member and other unrecited factors.
[0051] The height h of the first engaging end 103 and the height h'
of the second engaging end 106 are in the range of from 1 to 4
inches. The height h and h' can be shorter or longer than the
specifically recited ranges depending on the dimensions of the
storage rack, the weight of the load, the material of the formed
support member and other unrecited factors.
[0052] FIG. 2 illustrates a second embodiment of a formed support
member of the storage rack in accordance with aspects of the
present disclosure. The specific dimensions of the formed support
member are provided in FIG. 2A, which is a top view, FIG. 2B, which
is a front view and FIG. 2C, which is a side view. In particular,
the length l of the formed support member can be 38 to 42 inches.
In one example, the length is 41 3/16 inches. The width w of the
first engaging end 103 can be 2.5 to 4 inches. In one example, 31/4
inches. The height h of the first engaging end 103 can be 1.5 to
2.5 inches, in one example, 17/8 inches.
[0053] FIG. 3 illustrates a third embodiment of a formed support
member of the storage rack in accordance with aspects of the
present disclosure. The specific dimensions of the formed support
member are provided in FIG. 3A, which is a top view, FIG. 3B, which
is a front view and FIG. 3C, which is a side view. In particular,
the length l of the formed support member is 41 3/16 inches, the
width w of the first engaging end 103 is 31/4 inches, and the
height h of the first engaging end 103 is 23/8 inches.
[0054] FIG. 4A illustrates a top view of a deck structure 200, in
the form of a mesh of thick wires for a storage rack in accordance
with aspects of the present disclosure. Deck 200 comprises a
plurality of evenly spaced parallel rods (e.g., thick wires), for
example, 211, 212, 213, etc., that are substantially parallel to
the formed support members (not shown) and a plurality of evenly
spaced perpendicular rods, for example, 221, 222, etc., that are
substantially perpendicular to the formed support members (not
shown). The perpendicular rods are positioned underneath the
parallel rods to rest on the formed support members, with the
parallel rods thereon. The intersections of the parallel rods and
the perpendicular rods may be welded or joined by any other
conventional methods. The perpendicular rods shown in FIG. 4A can
have a length of 461/8 inches.
[0055] FIGS. 4B and 4C both illustrate front views of deck 200.
FIG. 4D illustrates a side view of deck 200. As shown in FIG. 4B,
both ends of the parallel rods 213 are bent to extend downwardly to
form a curved shape and substantially conform to the internal
concavity of a horizontal supporting C-beam or I-beam (not shown)
and the curvature of a formed support member (not shown) so that at
least a portion of the ends of the parallel rods are snugly fitted
between the horizontal supporting beam and the connection ends of
the formed support member. The perpendicular rods, for example, 221
and 222, are positioned underneath the parallel rod 213.
[0056] As shown in FIG. 4D, deck 200 further comprises a set of two
or three (or otherwise) fastening rods, for example, 231, 232 and
233, affixed on both ends of the parallel rods. The fastening rods
231, 232 and 233 are substantially parallel to the perpendicular
rods, for example, 221, and substantially perpendicular to the
parallel rods, for example, 211, 212 and 213. The fastening rods
are spaced to fit bolts of various sizes through the gaps
therebetween. As shown in FIG. 4B, the distance between the
fastening rods on both ends of a parallel rod is 41 3/16
inches.
[0057] FIG. 5A illustrates a top view of a system comprising deck
200 positioned on three formed support members 100 in accordance
with aspects of the present disclosure. Deck 200 is positioned on
three evenly spaced formed support members 100 as described
above.
[0058] FIG. 5B illustrates a cross sectional view along plane "A"
of deck 200 and one of the three formed support members 100 in
accordance with aspects of the present disclosure. Both ends of the
parallel rods 214 extend downwardly to form a curvature shape and
substantially conform to an internal concavity 311 or 321 of a
horizontal supporting beam 310 or 320, respectively, and the
curvature of formed support member 100, so that at least a portion
of the end of the parallel rods are snugly fitted between
horizontal supporting beam 310 and 320 and connecting ends of
formed support member 100.
[0059] As shown in FIG. 5B, parallel rods, for example, 214, may
comprise a downward slope in a representative length of 21/2
inches, so the top surface of the horizontal supporting beams 310
and 320 and the top surface of the parallel rods, for example, 211,
212, 213 and 214, of the deck 200, altogether form a flat surface
to support the loads. Since the formed support members 100 are
securely fastened and protected by the deck 200 and the horizontal
supporting beams 310 and 320, the system claimed herein is
structurally steady and does not interfere with the operations of
loading and unloading.
[0060] The deck is configured such that the upper storage surface
formed by the parallel rods is substantially in the same plane as
an upper surface of the horizontal support member.
[0061] FIG. 5C illustrates a front end side view of the deck being
positioned and supported by three formed support members 100 in
accordance with aspects of the present disclosure. The
perpendicular rods, for example, 221, are substantially in contact
with supporting surface 101 of formed support members 100 so that
the formed support member provides sufficient support to the deck
200 above.
[0062] As shown in FIG. 5C, all three formed support members 100
have one hole 104, and deck 200 has three fastening rods 231, 232
and 233. The holes 104 on the formed support members 100 are
aligned with the bolt receiving space between fastening rods 232
and 233 to receive a bolt therethrough to fasten member s 100 to a
horizontal support beam, not shown.
[0063] FIGS. 6A and 6B illustrate front end side views of a second
embodiment of a system comprising a deck of a storage rack
positioned on three formed support members 100 in accordance with
aspects of the present disclosure. In this embodiment of the
system, holes 104 on formed support members 100 are aligned with
the space between fastening rods 231 and 232.
[0064] FIGS. 7A and 7B illustrate side views of a third embodiment
of a system comprising a deck of a storage rack positioned on three
formed support members in accordance with aspects of the present
disclosure. In this embodiment of the system, the holes on the
formed support members are aligned with the space between fastening
rods 232 and 233.
[0065] The formed support member 100 may comprise one, two or three
(or more) holes on the first engaging end and the second engaging
end to accommodate different sized horizontal supporting beams and
decks so that once a storage surface deck is positioned above one
or more formed support members, at least one hole on the engaging
ends of the formed support member is aligned with a space between
two adjacent fastening rods for insertion of a bolt. Similarly, the
deck may comprise a set of two, three, four or more fastening rods
on both ends of the parallel rods to accommodate different sized
horizontal supporting beams and formed support members, so that
once a deck is positioned above one or more formed support members,
at least one space between two adjacent fastening rods is aligned
with a hole on the engaging ends of the formed support member.
[0066] In further embodiments of the invention, a formed support
member having two holes on the engaging ends and a deck being
assembled in accordance with aspects of the present disclosure is
provided. The holes are configured to permit proper attachment to
and alignment with either a 3'' horizontal support member or a 4''
horizontal support member, while maintaining proper support for the
deck.
[0067] In a further embodiment of the formed support member of the
present invention, the width w of the first engaging end 103 and
the width w' of the second engaging end 106 are reduced so that the
entire first engaging end 103 and the entire second engaging end
106 are positioned between two parallel rods, for example, 215 and
216 in FIG. 5A, so that any possible rotation introduced during the
fastening process would be avoided or at least partially
reduced.
[0068] The formed support member and storage surface grating can be
fabricated from suitable materials, including, but not limited to,
metal(s), including alloy(s), or combinations thereof, etc.
Suitable metals include aluminum, copper, iron, tin, lead,
titanium, zinc and etc. Suitable alloys including steel, solder,
brass, pewter, duralumin, bronze, amalgams and etc. The formed
support member may be fabricated from a single material or a
combination of materials, including, but not limited to, the above
exemplary materials, to achieve various desired characteristics
such as strength, rigidity, performance and durability. Preferred
support members are formed from a single piece of metal
material.
[0069] The present disclosure is advantageous because the ends of
the grating and the ends of the underneath formed support members
are embraced by the horizontal supporting beams of a storage rack.
As shown in FIG. 3, the exposed portion of the grating forms a flat
supporting surface substantially in the same plane defined by the
top surface of the horizontal supporting beams. Problems of formed
support members being interfere with the loading and unloading
processes are reduced, thereby improving the stability and
reliability of the storage rack.
[0070] A heavy-duty support member 800 in accordance with another
embodiment of the invention is shown generally in FIGS. 8-11.
Heavy-duty support member 800 is more conveniently constructed to
support heavier loads and span greater distances between horizontal
support beams, as compared to formed supporting member 100. Support
member 800 has the cross section of an angle bracket and a central
support section 810 in the form of an angle beam. Central section
810 includes a horizontal top wall 815 and a vertical side wall
817. Top wall 815 defines a substantially flat, horizontal load
bearing surface and side wall 817 depends vertically, and a right
angle, from top wall 815. The cross section of central section 810
has the shape of an "L", with top wall 815 meeting side wall 817 at
a vertex 816.
[0071] Support member 800 includes a connection bracket 820 at both
ends thereof, to secure support member 800 to a horizontal support
beam, as illustrated, for example, in FIGS. 13-15. Connection
bracket 820 has the shape and construction of an angle bracket, and
includes a connection arm 821 connected to an engagement arm 823,
joined at a bracket vertex 822. Connection arm 821 of connection
bracket 820 can be welded or otherwise attached to central section
810.
[0072] Preferably, connection arm 821 is joined to an outer surface
of side wall 817. An upper edge 825 of connection bracket 820
should be offset from the top surface of horizontal top wall 815.
In addition, connection bracket 820 should be offset from an end
819 of central section 810 with an offset gap 840. This permits
heavy-duty support member 800 to nest in the concave recess of a
C-beam (or I-beam) with the top flange of the C-beam extending into
the gap, so that engagement arm 823 can be flat with the horizontal
wall of the C-beam and top wall 815 can be on the same plane as the
top flange of the C-beam. One or more bolt receiving holes 829 is
provided to secure support member 800 to the horizontal support
beam.
[0073] Another embodiment of the heavy-duty support member is shown
generally as support member 801 in FIG. 12. Support member 801
includes a top wall 815 meeting at side wall 817 at a vertex 816,
as in support member 800. However, rather than attach a separate
connection bracket 820, support member 801 includes a formed
engagement end 830.
[0074] Support members 800 and 801 are preferably 30 to 50 inches
long, preferably 36-48 inches long or more. Lengths of 4 to 5 feet
and longer are possible.
[0075] Engagement end 830 is formed by slicing the ends of vertex
816 to form a horizontal flap 831 of top wall 815 and a vertical
flap of side wall 817. The vertical flap can be trimmed, as in FIG.
12 or bent out of the way. Horizontal flap 831 is initially bent
downward, to conform to the inner concave surface of the C-beam
where horizontal flap 831 extends from top wall 815 and is bent
further, to form an engagement surface 832 with a bolt receiving
hole 833 therethrough. engagement surface 832 is formed to conform
to the flat vertical wall of the C-beam, to join heavy-duty support
member 801 to the horizontal support beam.
[0076] FIGS. 13 and 14 depict a support member 800 having a storage
surface deck structure 250 thereon. Deck structure 250 includes an
array of lower perpendicular rods 260, with an array of upper
parallel rods 270 perpendicular to rods 260. Rods 260 can be welded
or otherwise joined to rods 270 in form a rectangular mash to
support pallets, cartons and other merchandise thereon. Each end
280 of deck 250 is bent downward, to conform to the inner concave
shape of a horizontal support beam 850. Ends 280 of deck 250
include a plurality of engagement rods 261, 262 and 263. A bolt 270
is inserted through a bolt receiving hole through horizontal
support beam 850, in a bolt receiving space between two of the
engagement rods 261 and 262 and through bolt receiving hole 829
through engagement bracket 820. The various parts should be sized,
arranged and configured, so that an upper surface of parallel rods
270 conforms to an upper surface 851 of horizontal support beam
850. This will help facilitate loading and unloading of objects
from deck 250.
[0077] All a fully assembled storage system 900 is shown generally
in FIGS. 15-17. Storage system 900 includes a plurality of vertical
columns 910 which are stably secured to a substrate floor surface.
A plurality of horizontal beams 850 are bolted, or otherwise
secured to columns 910. A plurality of support members 800 are
secured to horizontal beams 850. A deck structure 250' rests on
support members 800. The ends of deck structure 250' bend downward,
and fit between engagement ends 823 of support members 850. A bolt
270 extends through a bolt receiving hole through horizontal beam
850, between engagement rods 261 and 262 of deck 250' and through
hole 829 on the engagement surface 823 of engagement bracket
820.
[0078] Alternative embodiments of support members having two holes
on the engaging ends and a deck being assembled in accordance with
aspects of the present disclosure. The holes can be configured to
permit proper attachment to and alignment with either a 3, 3.5, or
4 inch horizontal support member, while maintaining proper support
for the deck.
[0079] In a further embodiment of the formed support member of the
present invention, the width w of the first engaging end and the
width w' of the second engaging end are reduced, so that the entire
first engaging end 10 and the entire second engaging end are
positioned between two parallel rods, for example, 215 and 216 in
FIG. 5A, so that any possible rotation introduced during the
fastening process would be avoided or at least partially
reduced.
[0080] The formed support member and grating can be fabricated from
suitable materials, including, but not limited to, metal(s),
alloy(s), or combinations thereof, etc. Suitable metals include
aluminum, copper, iron, tin, lead, titanium, zinc and etc. Suitable
alloys including steel, solder, brass, pewter, duralumin, bronze,
amalgams and etc. The formed support member may be fabricated from
a single material or a combination of materials, including, but not
limited to, the above exemplary materials, to achieve various
desired characteristics such as strength, rigidity, performance and
durability.
[0081] The present disclosure is advantageous because the ends of
the grating and the ends of the underneath formed support members
are embraced by the horizontal supporting beams of a storage rack.
As shown in FIG. 3, the exposed portion of the grating forms a flat
supporting surface substantially in the same plane defined by the
top surface of the horizontal supporting beams. The problems of
formed support members interfering with the loading and unloading
processes are reduced, thereby improving the stability and
reliability of the storage rack.
[0082] While the above description contains many specifics, these
specifics should not be construed as limitations of the invention,
but merely as exemplifications of preferred embodiments thereof.
Those skilled in the art will envision many other embodiments
within the scope and spirit of the invention as defined by the
claims appended hereto.
* * * * *