Abstract:
A rack step tool for use, for example, in a warehouse which houses a plurality of storage racks which support equipment, merchandise, or other items which are stored on the shelves of the storage racks and from which the equipment, merchandise, or other items are periodically removed. The rack step tool generally includes a step member which is attached to a base plate. A pair of lugs is attached to the base plate for insertion into openings in a vertical support member of the storage rack. The rack step tool can be attached to the vertical support member at various heights and can be readily disengaged therefrom. The rack step tool may further have a securing element such as a hook for insertion into another hole in the support member for further securing the rack step tool thereto.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   The present application claims the benefit of the priority date of U.S. Provisional Application No. 60/439,773, filed Jan. 10, 2003, the entirety of which is hereby expressly incorporated by reference herein in its entirety. 

   BACKGROUND 
   The present invention relates to devices which can be attached to and removed from a storage rack for enabling a user to step up and ascend a portion of the storage rack. 
   Storage racks are commonly used in warehouses and other storage facilities for supporting merchandise, boxes or pallets which support boxes or other items. It is often desirable for a worker to be able to ascend a portion of the storage rack to be able to remove or have access to items stored on the shelves of the storage rack. 
   A rack is typically constructed of at least two metal vertical support elements and one or more horizontal shelves. The shelves support the items, which often comprise boxes or cartons. The vertical support elements are typically constructed of metal and generally have a plurality of regularly spaced holes which can be used for bolts or screws or other attaching means which are attached to the shelves. Examples of such storage racks can be found in U.S. Pat. Nos. 3,303,937; 4,113,110; 4,549,665; 5,463,966; and 5,713,476, for example. The position of the shelves, bolts and screws can therefore be adjusted. 
   Currently, workers who wish to remove items from shelves of the storage racks described above are often forced to stand on a box, fork lift, tugger or pallet jack or on the lower most shelf of the rack and reach up and attempt to grab a box or carton either by a hand or by using hook-type device. Often a person will damage merchandise on a lower shelf by stepping on the carton or merchandise, or can damage contents in the carton by scrapping or puncturing it with the hooking tool. Furthermore, the person can sometimes topple the carton onto himself or onto the floor when pulling the carton off the rack or may fall off the forklift or box he is standing on. 
   It would be desirable for such a warehouse worker to have a step device which could be easily inserted into and removed from a portion of a storage rack to enable the worker to more readily and safely reach items stored at various heights and lateral positions on the storage rack. It is to this object that the present invention is directed. 
   SUMMARY OF THE INVENTION 
   The present invention is a rack step tool for use, for example, in a warehouse which houses a plurality of storage racks which support equipment, merchandise, or other items which are stored on the shelves of the storage racks and from which the equipment, merchandise, or other items are periodically removed. 
   The rack step tool generally includes a step member which is attached to a base plate. A pair of lugs is attached to the base plate for insertion into openings in a vertical support member of the storage rack. The rack step tool can be attached to the vertical support member at various heights and can be readily disengaged therefrom. The rack step tool may further have a securing element such as a hook for insertion into another hole in the support member for further securing the rack step tool thereto. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the rack step tool of the present invention and is shown as disposed adjacent a vertical support member of a storage rack. 
       FIG. 2  is a side elevational view of the rack step tool of  FIG. 1 . 
       FIG. 3  is a side elevational view of the rack step tool of  FIG. 1  when attached to the vertical support member of  FIG. 1 . 
       FIG. 4  is a rear elevational view of the rack step tool of  FIG. 1 . 
       FIG. 5  is a rear elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 6  is a side elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 7  is a side elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 8  is a side elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 9  is a side elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 10  is a top plan view of the rack step tool of  FIG. 9 . 
       FIG. 11  is a side elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 12  is a side elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 13  is a rear elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 14  is a top plan view of the rack step tool of  FIG. 13 . 
       FIG. 15  is a rear elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 16  is a rear elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 17  is a side elevational view of the rack step tool of  FIG. 16 . 
       FIG. 18  is a front elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 19  is a front elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 20  is a side elevational view of the rack step tool of  FIG. 19 . 
       FIG. 21  is a front elevational view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 22  is a top plan view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 23  is a top plan view of an alternate embodiment of the rack step tool of the present invention. 
       FIG. 24  is a front elevational view of an alternate embodiment of the rack step tool of the present invention. 
   

   DESCRIPTION OF THE INVENTION 
   The present invention is a device which provides an adjustable step which can be adjustably secured to the vertical support member of a storage rack. The user can insert lugs of the device into openings of the vertical support member of the storage rack, wherein the user can then step on the device for reaching cartons or boxes placed at various locations on the shelves of the storage rack. The position of the step tool can be adjusted upwardly or downwardly on the vertical support member of the storage rack to match the particular height or need of the user. 
   Turning now to  FIGS. 1–4 , a rack step tool  10  is shown. The rack step tool  10  comprises a base plate  12  having a front surface  14 , a back surface  16 , an outer perimeter  18 , an upper end  20  and a lower end  22 . The base plate  12  is preferably constructed of metal such as steel or aluminum. The base plate  12  has a vertical axis  24  represented on the back surface  16 , thereof. The vertical axis  24  separates the back surface  16  into a right side  26  and a left side  28 . A step member  30  is attached to the base plate  12 , generally to the front surface  14  thereof, and is preferably welded thereto or attached in any other manner known to those of ordinary skill in the art. The step member  30  is preferably constructed from a tubular metal pipe and preferably extends laterally in both directions perpendicular to the vertical axis  24  of the base plate  12 . The support member  30  preferably extends 4 inches to 10 inches beyond the outer perimeter  18 , and more preferably extends 6 inches to 8 inches beyond the outer perimeter  18 . The step member  30  has a front surface  32 , a back surface  34  to which the base plate  12  is generally attached, an upper surface  36  and a lower surface  38 . The step member  30  has a first end  40  and a second end  42  and a lumen  44  therein when the step member  30  is a pipe. Preferably the step member  30  has a non-slip or anti-skid surface  46  on at least a portion of the upper surface  36 . Materials for forming such anti-skid surfaces  46  are well known in the art. A first end plug  48  preferably covers the first end  40  and a second end plug  50  preferably covers the second end  42 . 
   The rack step tool  10  further comprises a pair of lugs comprising an upper lug  52  which is attached to the base plate  12  and extends outwardly from the back surface  16  thereof and a lower lug  62  which is attached to the base plate  12  and extends outwardly from the back surface  16  thereof. The upper lug  52  and lower lug  62  preferably are offset in relation to the vertical axis  24 . In particular, one of the upper lug  52  and the lower lug  62  extends from the right side  26  of the back surface  16  and the other of the upper lug  52  and the lower lug  62  extends from the left side  28  of the back surface  16 . In the embodiment of  FIGS. 1–4 , the upper lug  52  is on the right side  26  and the lower lug  62  is on the left side  28 . The offset nature of the upper lug  52  and lower lug  62  serves to help stabilize the rack step tool  10  on the storage rack during use. The upper lug  52  has a right side  54 , a left side  56  and a lower side  58 . Preferably, the upper lug  52  has a notch  60  therein, and in  FIGS. 1–4  the notch  60  is shown as being positioned in the lower side  58  of the upper lug  52 , preferably in a position directly adjacent the back surface  16  of the base plate  12 . The lower lug  62  has a right side  64 , a left side  66 , and a lower side  68 . Preferably the lower lug  62  has a notch  70  therein and in  FIGS. 1–4  is shown as being in the lower side  68 , preferably in a position adjacent the back surface  16  of the base plate  12 . 
   The upper lug  52  and lower lug  62  preferably extend at least slightly downwardly from the back surface  16  of the base plate  16 . Upper lug  52  extends from the back surface  16  at a first angle  72  while the lower lug extends from the back surface  16  at a second angle  74 . Preferably first angle  72  and second angle  74  are 60° to 90°, more preferably from 75° to 90°, still more preferably from 85° to 90° and most preferably from 86° to 88°. 
   As noted above, the upper lug  52  and lower lug  62  are positioned on opposite sides of the vertical axis  24  wherein a diagonal line  76  which extends between the upper lug  52  and the lower lug  62  transects the vertical axis  24  at a transection angle  78 . The transection angle is generally from about 7.5  to 75°, is more preferably from 10° to 60°, more preferably from 12.5° to 45° and most preferably from 15° to 30°. 
   The rack step tool of the present invention preferably further comprises a securing element  80  as shown in the rack step tool  10  of  FIGS. 1–4 . Preferably the securing element  80  comprises a hook or a similar mechanism for hooking into a portion of a storage rack. 
   The rack step tool  10 , as noted above, is constructed to engage a vertical support member  82  of a standard storage rack (not shown). The vertical support member  82  as represented in  FIG. 1  typically has a plurality of pairs of openings in a front surface  84  thereof. The plurality of pairs of openings may include for example a first pair of openings  86  which comprise a left opening  88  and a right opening  90 , a second pair of openings  92  which comprise a left opening  94  and a right opening  96 , and a third pair of openings  98 , which comprises a left opening  100  and a right opening  102 . 
   As shown in  FIG. 3 , the rack step tool  10 , when in use, engages the vertical support member  82  of the storage rack. The upper lug  52  is inserted into the right opening  90  of the first pair of openings  86 , the lower lug  62  is inserted into the left opening of the second pair of openings  92 , and the securing element  80 , is inserted into the right opening  102  of the third pair of openings  98  which is positioned above the right opening  90 . The back surface  16  of the base plate  12  rests more or less against the front surface  84  of the vertical support member  82 . The notch  60  of the upper lug  52  slides over a lower edge in the right opening  90  and the notch  70  of the lower lug  62  slides over a lower edge in the left opening  94 . The user is then able to step on a left hand or right hand portion of the step member  30  to ascend or climb the storage rack to retrieve an item disposed thereon. Although the upper lug  52  and lower lug  62  are shown as being offset in a preferred embodiment, the upper lug  52  and lower lug  62  may be vertically oriented on the base plate  12  such that a line drawn between them is parallel or congruent to the vertical axis  24  of the base plate  12 . 
   In a preferred embodiment (though the invention is explicitly not to be limited as such) the step member  30  is about 18 inches long and has a 1 inch diameter. The base plate  12  has a width of about 3 inches and a height between the upper end  20  and lower end  22  of about 6 inches. The upper lug  52  and lower lug  62  extend about 1 to 4 inches from the back surface  16 . The centers of the left opening and right opening of each pair of openings in the vertical support member  82  are about 1.5 inches apart and the centers of adjacent right openings are about 4 inches apart. The rack step tool  10  is preferably constructed of a metal, but may be constructed of any suitable material such as a thermoplastic polymer or a composite resin, in all or in part. 
   As noted above, the upper lug  52  of rack step tool  10  is positioned on the left side  28  of the back surface  16  while the lower lug  62  is positioned on the right side  26 . In any of the embodiments of the present invention described herein, the positions of the pair of lugs may be switched. For example, shown in  FIG. 5  is a rack step tool  10   a  having a base plate  12   a , having a back surface  16   a , an outer perimeter  18   a , a vertical axis  24   a , a right side  24   a , a left side  28   a , a step member  30   a , an upper lug  52   a , a lower lug  62   a  and a securing element  80   a . The upper lug  52   a  is positioned on the right side  26   a  and the lower lug  62   a  is positioned on the left side  28   a . The rack step tool  10   a  functions the same as rack step tool  10  in all regards. 
   Other embodiments of the present invention come readily to mind. For example, shown in  FIG. 6  is a rack step tool  10   b  having a base plate  12   b , a step member  30   b , an upper lug  52   b , a lower lug  62   b , and a securing element  80   b . Rack step tool  10   b  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that the upper lug  52   b  has a hook configuration, rather than a rod-like configuration, for hooking into an opening of the vertical support member  82 . 
   Shown in  FIG. 7  is a rack step tool  10   c  having a base plate  12   c , a step member  30   c , an upper lug  52   c , a lower lug  62   c , and a securing element  80   c . The rack step tool  10   c  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that lower lug  62  has a hook configuration. 
   Shown in  FIG. 8  is a rack step tool  10   d  having a base plate  12   d , a step member  30   d , an upper lug  52   d , a lower lug  62   d , and a securing element  80   d . Rack step tool  10   d  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that both the upper lug  52   d  and lower lug  62   d  have hook configurations rather than rod-like configurations. 
   Shown in  FIGS. 9 and 10  is a rack step tool  10   e  having a base plate  12   e , a step member  30   e , an upper lug  52   e , a lower lug  62   e , and a securing element  80   e . Rack step tool  10   e  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that the step member  30   e  is not a tubular pipe but rather has a flat configuration which extends perpendicularly a distance from a front surface  14   e  of the base plate  12   e.    
   Shown in  FIG. 11  is a rack step tool  10   f  having a base plate  12   f , a step member  30   f , an upper lug  52   f , a lower lug  62   f , and a securing element  80   f . Rack step tool  10   f  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that the step member  30   f  has a “V” configuration rather than a tubular configuration. 
   Shown in  FIG. 12  is a rack step tool  10   g  having a base plate  12   g , a step member  30   g , an upper lug  52   g , a lower lug  62   g , and a securing element  80   g . Rack step tool log is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that step member  30   g  is hollow and has a square cross-section. 
   Shown in  FIGS. 13 and 14  is a rack step tool  10   h  having a base plate  12   h , a step member  30   h , an upper lug  52   h , a lower lug  62   h , and a securing element  80   h . Rack step tool  10   h  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that a notch  60   h  is positioned in a right side  54   h  of upper lug  52   h  and a notch  70   h  is positioned in a left side  66   h  of lower lug  62   h . Notch  60   h  and notch  70   h  are configured in the right side  54   h  and left side  66   h , respectively, for engaging a tapered lower edge of “keyhole”-shaped openings in a typical vertical support element  82  of a storage rack, for example such as those seen in U.S. Pat. No. 3,303,937. 
   Shown in  FIG. 15  is a rack step tool  10   i  having a base plate  12   i , a step member  30   i , an upper lug  52   i , a lower lug  62   i , and a securing element  80   i . Rack step tool  10   i  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that a notch  60   i  is positioned in a left side  56   i  of upper lug  52   i  and a notch  70   i  is positioned in a right side  64   i  of lower lug  62   i . Notch  60   i  and notch  70   i  are configured in the left side  56   i  and right side  64   i , respectively, for engaging a lower edge of “keyhole”-shaped openings in a typical vertical support element  82  of a storage rack as noted above. 
   Any of the rack step tools  10 – 10   i  may have additional notches in the lower side or left or right sides thereof for additional effectiveness in engaging to a lower edge of an opening of the vertical support element  82 . 
   Shown in  FIGS. 16 and 17  is a rack step tool  10   j  having a base plate  12   j , a step member  30   j , an upper lug  52   j , a lower lug  104   j , and a securing element  80   j . Rack step tool  10   j  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that the lower lug  104  is a flange, rather than a rod or hook, and is attached to and extends from or near to a lower edge of the base plate  12   j . The lower lug  104  preferably sits astride an outer edge of the vertical support element  82  rather than inside an opening thereof when the rack step tool  10   j  is secured to the vertical support element  82 . 
   Shown in  FIG. 18  is a rack step tool  10   k  having a base plate  12   k , a step member  30   k , an upper lug  52   k , a lower lug  62   k , and a securing element  80   k . Rack step tool  10   k  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that rack step tool  10   k  has a hook extension  106  which can telescopically extend from and back into the step member  30   k . Preferably the hook extension  106  can be locked into place via a locking device  108  in the step member  30   k . The hook extension  106  can be used by a user of the rack step tool  10   k  to hook and retrieve boxes or items on the storage rack. 
   Shown in  FIGS. 19 and 20  is a rack step tool  10   m  having a base plate  12   m , a step member  30   m , an upper lug  52   m , a lower lug  62   m , and a securing element  80   m . Rack step tool  10   m  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that the base plate  12   m  is constructed of an upper portion  110  and a lower portion  112 . The upper portion  110  is connected to and extends from an upper portion of the step member  30   m  and the lower portion  112  is connected to and extends from a lower portion of the step member  30   m . It will be understood by a person of ordinary skill in the art that the step member  30  in any embodiment herein may be constructed to the base plate at an upper, middle, or lower portion thereof. 
   Shown in  FIG. 21  is a rack step tool  10   n  having a base plate  12   n , a step member  30   n , an upper lug  52   n , a lower lug  62   n , and a securing element  80   n . Rack step tool  10   n  is the same as either of rack step tools  10  or  10   a , or any other rack step tool embodied herein except that the securing element  80   n  is a chain, wire or other tying mechanism which is designed to loop around a back of the vertical support member  82  and reattach to a portion of the base plate  12   n  thereby securing the base plate  12   n  to the vertical support member  82 . 
   Shown in  FIG. 22  is an alternate embodiment of the present invention. Rack step tool  10   p  has a step member  30   p , a securing element  80   p , and a pair of lugs  114  and  116  which are attached directly to the step member  30   p . Shown in  FIG. 23  is another embodiment of the invention and is similar to rack step tool  10   p . Rack step tool  10   q  of  FIG. 23  has a step member  30   q , a securing element  80   q , and four lugs,  118 ,  120 ,  122 , and  124 , which are designed to fit into four parallel openings in a vertical support member having openings in such a configuration. 
   Shown in  FIG. 24  is a rack step tool referred to by the general reference numeral  10   r  which is similar to the other embodiments herein in having a base plate  12   r  and a step member  30  except the rack step tool  10   r  has two pairs of lugs, including an upper pair comprising a left upper lug  126  and a right upper lug  128 , and a lower pair comprising a left lower lug  130  and a right lower lug  132 . Rack step tool  10   r  functions in a manner similar to rack step tool  10  or any other rack step tool embodiment herein, except when rack step tool  10   r  is engaged with the vertical support member  82 , left upper lug  126  and right upper lug  128  fit into openings  90  and  88 , and left lower lug  130  and right lower lug  132  fit into openings  96  and  94  of the vertical support element  82 . 
   The present invention comprises not only devices such as rack step tools  10 – 10   r  described herein, and variations thereof, but also includes methods of using the tool in conjunction with a storage rack and includes the rack step tool  10 – 10   r  in combination with a storage rack or any portion thereof to which the tool may be attached. 
   When the rack step tool  10 – 10   r  is being attached to the vertical support member  82  of the storage rack, the rack step tool  10 – 10   r  is not twisted or rotated more than a few degrees to be secured to the vertical support member  82 , and then only to be snugly seated in the openings of the vertical support member  82 . The step member  30 – 30   r  of the rack step tool  10 – 10   r  extends perpendicularly from the vertical support member  82  either from the front surface of the vertical support member  82  or from a side edge thereof. 
   Changes may be made in the construction and the operation of the various components, elements and assemblies described herein or in the steps or the sequence of steps of the methods described herein without departing from the spirit and scope of the invention as defined in the following claims.