Abstract:
The disclosed warehouse loader has two platform sections. One section is hinged to a deck where the operator stands when moving the loader. The other section is hinged to the first section and can be aligned with the first section to create a platform that extends outwardly from the deck and can be accessed by the operator directly from the deck. The second section is narrower than and folds against the first section. A spring-loaded latch holds the first section in an upright position, with the second section folded against it. A manually-operable positioning hook engages receptacles in the platform sections, making it easier to fold the sections. To retrieve a spilled article, the loader is first positioned at an open location adjacent the spilled article. The platform is extended into the open location. The operator can then stand on the platform while retrieving the article.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to the operation of warehouses, and more particularly to the problem of retrieving articles that may spill from warehouse locations. 
     Conventionally, workers climb into the racks with or without the assistance of ladders. Retrieval of spilled articles often involves strenuous reaching or bending, which can be dangerous. 
     BRIEF SUMMARY 
     The applicants have developed a modification for conventional warehouse loaders that may provide a safer way to retrieve spilled articles. Unlike other known loaders, the new loader has two extendable platform sections. One of those sections is hinged to an operating deck that is adjacent to and directly accessible from a driving deck where the operator can stand when moving the loader. The other section is hinged to a distal end of the first platform section and can be aligned with the first section to create a platform that extends outwardly from the deck and can be accessed by the operator directly from the deck. 
     For use in this particular context, it may be preferred that the platform sections are each between 12 and 36 inches wide, can support 300 pounds of weight, and weigh less than 40 pounds. It may also be preferred that the platform sections are extendable outwardly from a side of the loader. 
     In some instances, options can be implemented to facilitate use and storage of the platform sections. For example, the second platform section can be made 1-3 inches narrower than the first platform section, and can be arranged so that it folds against one side of the first extendable platform section. A spring-loaded latch can be arranged to selectively hold the first section in an upright position, with the second section folded against one side of the first section. A manually-operable positioning hook can also be provided to allow the user to selectively engage receptacles in the platform sections, making it easier to fold or unfold the sections. 
     To retrieve a spilled article, the warehouse loader is first positioned at an open location adjacent the spilled article. This may be, for example, an open pallet location. The foldable platform is then extended from the first section into the open location. It may be supported by pallet supports in that location. The operator can then stand on the foldable platform while retrieving the spilled article. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may be better understood by referring to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of portions of one kind of warehouse loader that embodies the invention. 
         FIG. 2  is a perspective view of an operating assembly that is shown on the loader of  FIG. 1 . 
         FIG. 3  is a perspective view of the assembly, with the platform extended. 
         FIG. 4  is a detail view of a corner of the assembly. 
         FIGS. 5 and 6  are perspective and side views of a positioning hook that can be used with the assembly. 
         FIG. 7  is a perspective view of the loader in use. 
         FIGS. 8 and 9  are detail views of the platform being extended into a warehouse location. 
         FIGS. 10-13  are perspective views of an operator extending the platform sections. 
         FIG. 14  is a perspective view of an operator using the platform sections to retrieve a spilled article. 
         FIGS. 15 and 16  are perspective views of an operator re-folding the platform sections. 
         FIG. 17  is a perspective view of a mechanism that can be used to lock the platform sections in a folded position. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a warehouse loader, generally denoted by reference number  10 . This warehouse loader  10  includes an assembly  11  carried on the forks of an order selector typically used within a warehouse environment. As shown in  FIG. 2 , the assembly  11  of the illustrated warehouse loader  10  includes an operating deck  12  that is made of material strong enough to support a weight of 300 pounds. The operator can stand on the operating deck when moving the loader up and down. This deck  12  may be constructed of such materials as wood or diamond plate steel and may have a non-slip coating applied as a safety feature. The operating deck  12  may be sized to various standard pallet dimensions, such as to 40 inches wide by 48 inches deep, for example. The operating deck  12  is adjacent to and can be accessed directly from a driving deck  13  on an order selector  78  ( FIG. 1 ). 
     As shown in  FIG. 2 , the operating deck  12  may have a hinge  14  attached along its entire depth from front to back. This hinge  14  may be constructed as one continuous segment, such as a piano hinge, and may include one pin running the length of its joint. Other types of hinges can also be used. The illustrated hinge  14  connects the operating deck  12  to a first extendable platform section  16 , which may typically range from 12 to 36 inches in width. This hinge  14  may have a range of rotation “Θ” of at least about 0 to 90 degrees, e.g., allowing the first platform section  16  to move from a horizontal position (0 degrees) to a near vertical position (90 degrees). The first platform section  16  can be designed of material such as diamond plate, to support weight up to 300 pounds. Preferably, it weighs less than 40 pounds. 
     A comparable hinge  14  on a distal end of the first platform section  16  connects the first platform section, along its entire depth, to a proximal edge of a second extendable platform section  18 . The second platform section  18  may range from 12 to 36 inches in width as well. The illustrated second platform  18  section is 1-3 inches narrower than the first extendable platform section to facilitate folding. Like the first platform section  16 , the second platform section  18  is designed of material such as diamond plate, in order to support weight up to 300 pounds. Again, light weight is preferred. 
     The second hinge  14  that connects the two platform sections  16 ,  18  may have a range of rotation “ΘΘ” of 0 degrees to just less than 180 degrees.  FIG. 2  shows a final folded upright resting position of the two illustrated platform sections  16 ,  18 , with the second platform section  18  not quite folding flat against the upright first platform section  16 .  FIG. 3  shows the platform area that is created when both the first platform section  16  and the second platform section  18  are unfolded from their upright resting position and laid out horizontally, creating an extended platform that extends outwardly from the operating deck  12  and can be accessed by the operator directly from the operating deck and from the driving deck  13 . 
     As shown in  FIG. 3 , the illustrated first platform section  16  includes a positioning aperture  20  and the second platform section  18  includes two positioning apertures  20 . Each positioning aperture  20  is a location into which a positioning hook  32  (see  FIGS. 5 and 6 ) may be placed by an operator to more easily manipulate the platform section (see  FIGS. 12 ,  13 ,  15 , and  16 ). The manipulation would typically be either in an unfolding direction from an upright resting position (see  FIG. 2 ) to a horizontal position (see  FIG. 3 ), or in a folding direction from a horizontal position to an upright resting position. Although the position could vary, each illustrated positioning aperture  20  is located close to the middle of the width of its respective platform section  16 ,  18  and near to a front-to-back edge of that platform section. The illustrated locations of the positioning apertures  20  are intended to minimize the effort an operator needs to exert to fold and unfold the platform sections  16 ,  18 . 
       FIGS. 2 and 3  show other features that can be included in the warehouse loader  10 . A kick plate  22  is positioned above the rear edge and also above the left side edge of the operating deck  12 . This kick plate  22  may be made of diamond plate steel or other thin, strong material and can be positioned to keep the operator and/or any items that may be placed on the deck  12  from falling off. The front edge of the operating deck  12  is left open so that the operator can enter and exit the deck  12  from the driving deck  13  of the order selector  78  that carries the assembly  11 . The right side of the operating deck  12  is occupied by the folded platform sections  16 ,  18  and would thus not need a kick plate  22 . 
     Rising from three corners of the operating deck  12  are three uprights  24 . Along with two cross members  26  and two hand rails  28 , these uprights form a structure to contain the operator and the contents of the operating deck  12  during usage. This structure may be constructed of sections of the same material, such as square metal tubing, for example, and welded together for rigidity. Other materials and joining methods may be acceptable as long as the structure is constructed securely. A safety net  30  can also be attached to each upright  24 , cross member  26 , and hand rail  28  to aid in containing the operating deck contents. 
     In the back left corner of the operating deck  12 , the positioning hook  32  is stored upright within a positioning hook holder  34 . A typical positioning hook holder  34  may be constructed of a piece of PVC or similar tubing that may be hollow and may have a bottom end to enclose the positioning hook  32 . If there is no bottom end, then the positioning hook  32  may rest against the operating deck  12  when stored. The positioning hook holder  34  is preferably affixed in an upright position to the corner upright  24 , but other arrangements are possible. 
     The operating deck  12  rests upon and is supported by a right rail  36 , a left rail  38 , and a middle rail  40 . A non-slip coating  42  can be applied to each vertical surface of the middle rail  40  along its entire depth, from the front to the rear of the assembly  11  of the warehouse loader  10 . When used, this non-slip coating  42  may aid in providing a positive connection between the assembly  11  and the pallet locking mechanism of the order selector  78  (see  FIG. 1 ). A top rail  44  and a bottom rail  46  can be used to tie together the ends of the right rail  36 , the left rail  38 , and the middle rail  40 . In the illustrated device, a left slot  48  is created in the space between the left rail  38  and the middle rail  40 , underneath the top rail  44 , and above the bottom rail  46 . This left slot  48  accommodates the left fork of the order selector  78  ( FIG. 1 ) to support the assembly during use. Similarly, a right slot  50  is created in the space between the right rail  36  and the middle rail  40 , underneath the top rail  44 , and above the bottom rail  46 . This right slot  50  accommodates a right fork  76  of the order selector  78  to support the assembly  11  during use. 
     The assembly  11  of the illustrated warehouse loader  10  has a spring-loaded latch that is arranged to secure the platform sections  16 ,  18  while they are not in use.  FIG. 4  shows a detailed view of this latch. A handle  54  is connected to the top of a lever  56  that pivots around a hinge bolt  58  during use. This hinge bolt  58  feeds through apertures in the lever  56  and in a hinge bracket  60 , and is secured with a hinge nut  62 . The bottom of the lever  56  connects to a u-shaped bracket  64 , which is oriented perpendicularly to the plane of the lever  56 . The bracket  64  includes a platform latch end  70  that extends through an aperture in an upright  24 . The leading edge of the upright  24  includes a spring housing  68  that contains a spring  66  that is attached to the bracket  64 , biasing the latch end into the aperture in the upright. In that position, the latch end  70  projects into the unfolding path of the platform sections  16 ,  18 , thus obstructing the unfolding of those sections. Thus, this latch can selectively hold the first platform section  16  in an upright position, with the second platform section  18  folded against one side of the first platform section. 
     As shown in  FIG. 4 , as the handle  54  is pulled by the operator inwardly, the lever  56  will rotate around the hinge bolt  58 , and the latch end  70  will be pulled backward through the upright  24  (against the force of the spring  66 ), thus releasing the platform sections  16 ,  18  and allowing them to be unfolded and placed into an extended, horizontal position. 
     When platform sections  16 ,  18  are being rotated back into their upright folded positions, as they each pass the angled face of the latch end  70 , they will depress the spring  66  of the latch end, and the latch end will be forced backward through the upright  24 , thus allowing the platform sections  16 ,  18  to pass. A stop  72  can be included on the second end of the bracket  64  to limit the travel of the second platform section  18 , which is the first platform section to pass by the latch end  70 . 
       FIG. 5  shows a perspective view of one example of a positioning hook  32  and  FIG. 6  shows a side view of that hook. 
       FIGS. 1 and 7  show the assembly  11  positioned on the order selector  78 . Mounting the assembly  11  on an order selector allows the operator to conveniently enter the operating deck  12  from the driving deck  13  by stepping across a boundary  79  that separates the operating deck from the driving deck, without stepping off the loader, and will often be safest and preferred. 
     To retrieve a spilled article, the operator  80  first establishes an open location adjacent the spilled article. A pallet may need to be moved to establish an open location. The warehouse loader  10  is then moved adjacent the open location. Once the warehouse loader  10  is in a useful location, the order selector  78  can be used to raise the assembly  11  to the proper level to facilitate the transfer of shelf contents, whether for loading or unloading. 
       FIG. 7  shows the operator  80  standing upon the operating deck  12  of the assembly  11  of the warehouse loader  10 , checking the structural rigidity of a pallet support  82  onto which the platform sections  16 ,  18  of the warehouse loader  10  can be unfolded. The vertical positioning of the warehouse loader  10  is important for its safe usage. 
       FIG. 8  shows the warehouse loader  10  with its platform section  16  extended and resting on a pallet support  82 . As shown, a shelf rack  86  may support each shelf  84 . An angle “ΘΘΘ” is created between the plane of the platform section  16  and the horizontal. In general, the closer this angle “ΘΘΘ” is to zero degrees, the safer the vertical positioning is of the warehouse loader  10 .  FIG. 9  shows this angle “ΘΘΘ” at zero degrees and thus the platform sections  16 ,  18  are horizontal. The platform section  16  rests horizontally on the top surface of a shelf  84  as well as on top of each pallet support  82 , thus posing fewer safety risks for the operator  80 . The angle “ΘΘΘ” at zero degrees also results in less strain being placed upon the hinge  14  that is used to affix the first platform section  16  to the operating deck  12 , as to do otherwise could lead to premature failure of this hinge. 
       FIG. 10  shows the operator  80  pulling the lever  56  inward, thus releasing the latch end  70 , allowing the movement of the platform sections  16 ,  18  from their folded upright resting position. The operator&#39;s right hand is holding the platform sections  16 ,  18  until the positioning hook  32  is obtained. 
       FIG. 11  shows the operator&#39;s left hand obtaining the positioning hook  32 . 
       FIG. 12  shows the positioning hook  32  having been inserted in the positioning aperture  20  of the platform section  18 , with the operator  80  allowing gravity to slowly pull the platform section  16  downward toward a flat, unfolded position. After the platform section  16  reaches its final unfolded position, the operator  80  removes the positioning hook  32  from its current positioning aperture  20  and places it into the positioning aperture  20  on the opposite side of the same platform section  18 . The operator then proceeds to unfold the platform section  18 , as seen in  FIG. 13 , until it rests horizontally on the pallet supports  82 . 
       FIG. 14  shows the platform sections  16 ,  18  in their fully-extended horizontal position, with the operator  80  standing upon them, retrieving a spilled article  88 . Upon completion of the task, the operator  80  again places the positioning hook  32  into a positioning aperture  20  located on the platform section  18 , and, as seen in  FIG. 15 , proceeds to fold the platform section  18  until it reaches its maximum folded position (as far as hinge permits). The operator  80  then removes the positioning hook  32  from its current positioning aperture  20  and places it into the other positioning aperture  20  on the opposite side of the same platform section  18 , and, as shown in  FIG. 16 , proceeds to fold the platform sections  16 ,  18  toward their final upright resting position. The platform sections  16 ,  18  will then both brush past the angled face of the latch end  70  until the platform section  18  abuts the stop  72  (see  FIG. 17 ), and can travel no further. After the platform sections pass by the angled face of the latch end  70 , the spring  66  will force the latch end  70  back to its resting position, and the platform sections  16 ,  18  will be restrained from traveling in an outward direction away from the warehouse loader  10 .  FIG. 17  shows the final upright resting position of platform sections  16 ,  18 . 
     The illustrated latch mechanism keeps the platform sections  16 ,  18  from falling inward toward the operator  80  and outward away from the operator. Alternatively, the warehouse loader  10  may have other structural arrangements to restrain platform section  16 ,  18  in an upright resting position. These arrangements may include such restraining devices as latches, clamps, sliding bolts, hooks, etc. 
     This description of various embodiments of the invention has been provided for illustrative purposes. Revisions or modifications may be apparent to those of ordinary skill in the art without departing from the invention. The full scope of the invention is set forth in the following claims.