Abstract:
A storage surface assembly is provided for use as a shelf for holding storage items. This storage surface assembly is well suited for use in many industrial and/or commercial applications, where storage shelves must bear heavy loads and maintain their structural integrity while complying with fire codes requiring some amount of open area along the surface of the shelf. Therefore, there is provided a storage surface assembly for use in a standard commercial racking assembly, the storage surface assembly comprising a pair of extension members, and a plurality of traverse members extending between the pair of extension members, wherein the traverse members can be attached to the extension members by various methods, based on the requirements dictated by a particular storage environment.

Description:
[0001]     This application is a Continuation-In-Part of application Ser. No. 10/460,309 filed Jun. 13, 2003, the entirety of which is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates to a storage surface assembly for use as a shelf for holding storage items in industrial/commercial applications/environments.  
         [0004]     2. Background of the Related Art  
         [0005]     Storage shelves used in an industrial/commercial environment must often bear heavy loads while still maintaining their structural integrity, as well as resist the twisting and buckling forces generated when storage items are loaded, unloaded, or moved. These industrial storage shelves are also subjected to fire codes requiring some amount of “open area” along the surface of the shelf, dictated in most cases by the particular environment in which they will be used, as well as the types of items to be stored.  
         [0006]     The “open area” required by fire codes is typically 50% of the surface area of the shelf. This open area requirement was imposed to allow a fire in the storage area to be more efficiently contained and extinguished, thus minimizing damage to storage items. More specifically, a shelf with an adequate amount of open area allows a fire initiated on a lower shelf to move vertically up the storage rack, towards the sprinkler, allowing heat to dissipate more quickly and activating the sprinklers before the fire has gained significant intensity. Closed shelves (shelves with little to no open area), which may provide adequate load capacity and structural integrity, would, on the other hand, form an enclosed space between shelves, allowing a fire to build in intensity in that enclosed space, spread horizontally to a neighboring tack of shelves, and also delay deployment of the sprinkler system, rendering the sprinkler system significantly less effective in containing and extinguishing the fire. This 50% open area requirement poses a unique challenge in providing shelves with adequate structural integrity at a reasonable cost, while still meeting this open area requirement. Current solutions, such as those discussed below, are not adequate.  
         [0007]     Slatted wooden decking, although easily and inexpensively manufactured, has significant disadvantages in that it is less durable and mote susceptible to deformation than steel, and more likely to break under continued loading or changing environmental conditions. Its most significant disadvantage is that it is highly flammable.  
         [0008]     Wire mesh decking is a commonly used shelving solution in industrial/commercial applications. Wire mesh meets the 50% open area requirement, but, as wire mesh is simply laid across a series of cross bats, it remains unsupported across a majority of its load-beating surface, and thus deforms easily. Further, if one of the support bars is damaged, it cannot be repaired or replaced without removal of the entire wire mesh, most likely resulting in replacement of the entire deck as repair would not be cost effective. Additionally, due to the nature of the surface of wire mesh, especially after it has deformed, it is difficult to load/unload/move storage items without damaging the storage items and/or the wire mesh, as the mesh tends to catch on the storage items, producing rips, punctures, or impressions. Wire mesh decks are not easily manufactured or shipped, making them a more costly, less efficient shelving solution.  
         [0009]     U.S. Pat. No. 5,279,431 to Highsmith et al. discloses a storage tack with storages surfaces formed by crossbars with tangs extending from the ends which are then inserted into corresponding slots in the side beams. However, Highsmith&#39;s design is complicated, difficult and costly to manufacture, and the shelving system must be used with Highsmith&#39;s racking system and cannot be readily adapted for use in other racking systems. Further, as the bulk of the load on the storage surface is carried by a very small tang at the end of the crossbar, Highsmith&#39;s design cannot be used in commercial/industrial applications, where shelves must bear heavy loads while maintain g their structural integrity.  
         [0010]     Likewise, U.S. Pat. No. 5,628,415 to Mulholland also discloses a storage rack with safety bars fitted to support beams by mating tabs and slots. Mulholland&#39;s design is complicated, difficult and costly to manufacture, and is for an entire racking system whose shelves cannot be readily adapted for use with other racking systems.  
         [0011]     U.S. Pat. No. 5,199,582 to Halstrick discloses a storage rack which uses a corrugated plate to form each shelf. Although Halstrick&#39;s design incorporates holes in the corrugated sheet to allow for a very limited amount of open area, this design could not meet the 50% open area requirement with out affecting the structural integrity of the shelf.  
         [0012]     U.S. Pat. No. 6,401,944 to Kircher et al. discloses a storage rack similar to Halstrick&#39;s which does meet the 50% open area requirement. However, there are several disadvantages associated with Kircher&#39;s design. Kircher&#39;s corrugated deck is expensive to manufacture and ship, increasing cost to the user. If not properly secured in the rack, the deck elements can spread over time due to the load applied by the storage items, forcing the rack to carry more that its design load, thereby compromising the rack&#39;s structural integrity. Similar to wire mesh, the holes, unless properly finished, tend to shred storage items when they are loaded, unloaded and moved.  
         [0013]     The above references are incorporated by reference herein where appropriate for appropriate teachings of additional or alternative details, features and/or technical background.  
       SUMMARY OF THE INVENTION  
       [0014]     An object of the invention is to solve at least the above problems and/or disadvantages and to provide at least the advantages described hereinafter.  
         [0015]     According to the invention, therefore there is provided a storage surface assembly for use as a shelf for holding storage items in industrial or commercial environments. Some amount of the surface area of the storage surface assembly remains open in order to provide for adequate circulation of air, heat dissipation, and water flow, and meet current fire code requirements. The open area of the storage surface assembly would typically be at least 50% in order to comply with current fire codes. However, as will become apparent in the discussion that follows, the storage surface assembly may be adjusted to meet a variety of open area requirements, and is not limited to a 50% open area  
         [0016]     Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objects and advantages of the invention may be realized and attained as particularly pointed out in the appended claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]     The invention will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:  
         [0018]      FIG. 1  is a perspective view of a storage surface assembly according to an embodiment of the invention;  
         [0019]      FIGS. 2A-2B  are perspective views of extension members employable in a storage surface assembly according to an embodiment of the invention;  
         [0020]      FIG. 2C  is a cross sectional view of the extension members of  FIGS. 2A-2B ;  
         [0021]      FIG. 2D  is a perspective view of an alternative extension member according to an embodiment of the invention;  
         [0022]      FIG. 2E  is a perspective view of another alternative extension member according to an embodiment of the invention;  
         [0023]      FIGS. 2F-2H  are cross sectional views of stacked traverse members according to embodiments of the invention;  
         [0024]      FIGS. 2I-2M  are perspective views of alternative extension members and alternative traverse members according to embodiments of the invention;  
         [0025]      FIG. 2N  is a side view of the traverse member shown in  FIG. 2M  secured in the extension member shown in  FIG. 2M ;  
         [0026]      FIG. 3A  is a perspective view of a traverse member employable in a storage surface assembly according to an embodiment of the invention;  
         [0027]      FIG. 3B  is a cross sectional view of the traverse member of  FIG. 3A ;  
         [0028]      FIG. 3C  is a cross sectional view of a traverse member, in accordance with an embodiment of the invention;  
         [0029]      FIGS. 4A-4S  are cross sectional views of alternatively shaped traverse members according to embodiments of the invention;  
         [0030]      FIG. 5  is a top view of a storage surface assembly according to an embodiment of the invention;  
         [0031]      FIGS. 6A-6B  are top views of a storage surface assembly according to an embodiment of the invention showing alternate grouping configurations of traverse members;  
         [0032]      FIG. 7  is a front view of a tack beam assembly according to an embodiment of the invention incorporating a storage surface assembly according to the invention; and  
         [0033]      FIG. 8  is a perspective view of the rack beam assembly of  FIG. 7 . 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0034]      FIG. 1  is a perspective view of a storage surface assembly according to an embodiment of the invention. The storage surface assembly  100  of  FIG. 1  is constructed of a plurality of traverse members  20  attached to extension members  30  at attachment members  40  to form a surface area  36 . As shown in  FIG. 5 , at least a portion of the traverse members  20  are spaced apart from one another to form open spaces  50 . In order to meet current fire code requirements and in order to provide for adequate circulation of air, heat dissipation, and water flow, at least 50% of the surface area  36  remains open via the open spaces  50  formed between the traverse members  20 .  
         [0035]     It is well understood by one skilled in the art that the amount of surface area  36  that remains open can be either increased or decreased based on the number of traverse members  20  attached to a particular part of extension members  30 , as well as the positioning of the traverse members  20  along the extension members  30 . In this manner, the storage surface assembly  100  can be adapted to meet a variety of open area requirements.  
         [0036]     In the embodiment of  FIG. 1 , the extension members  30  comprise angle irons; however, other shapes and materials may also be appropriate. The number of traverse members  20  used in the construction of the storage surface assembly  100  can be adjusted to suit, for example, the size and load bearing capability requited for a particular application. However, the open air space must remain at least 50% for the above described reasons.  
         [0037]      FIGS. 2A-2B  are perspective views and  FIG. 2C  is a cross sectional view of an extension member  30  employable in a storage surface assembly in accordance with an embodiment of the invention. The extension members  30  of the embodiment of  FIGS. 2A-2C  comprise angle irons forming an angle θ of 90 degrees; however, other angles may also be appropriate, depending on the particular application. Likewise, the length a, width b and height c of the extension member  30  can be varied as necessary, depending, for example, on a particular application&#39;s size and load bearing requirements.  
         [0038]      FIG. 3A  is a perspective view and  FIG. 3B  is a cross sectional view of a traverse member  20  employable in a storage surface assembly in accordance with an embodiment of the invention. The exemplary traverse member  20  shown in  FIGS. 3A-3B  are formed in a  
                           
 shape, with a bottom width f larger than a top width e; however, the length d, top width e, bottom width f, and height g can be varied as necessary, depending on, for example, a particular applications size and load beating requirements. For example, in the traverse member  20  shown in  FIG. 3C , the bottom width is f substantially equal to the top width e, with the attachment members  40  curved inward. Likewise, a number of different cross sectional shapes, such as those shown in  FIGS. 4A-4S , may also be appropriate for the traverse members  20 . 
 
         [0039]     As shown in  FIG. 5 , the traverse members  20  are attached to the extension members  30  at attachment members  40 . The attachment members  40  serve to both fix the traverse members  20  in position along the extension members  30 , and also to inhibit spreading of the traverse members  20  due to the load applied by a storage item and subsequent loss of load bearing capability. The traverse members  20  which are used in fabricating a single storage surface assembly must not necessarily be of the same cross sectional shape, and traverse members  20  of different cross sectional shapes, such as, for example, combinations of those shown in  FIGS. 4A-4S , may be combined to form a single storage surface assembly.  
         [0040]     The traverse members  20  and extension members  30  can be made of a variety of different materials. Fabrication material may be selected based on, for example, load bearing requirements and the operating environment for a particular application, as well as cost. For example, in a storage application where humidity and environmental degradation are factors, both the traverse members  20  and extension members  30  may be made of a galvanized steel to inhibit material breakdown due to the environmental factors and subsequent loss of structural integrity. Likewise, in a storage application where cleanliness and appearance are factors, such as in a commercial kitchen, both the traverse members  20  and extension members  30  may be made of a stainless steel. Other materials may also be appropriate. Traverse members  20  and extension members  30  may not necessarily be fabricated from the same material. However, attachment methods and environmental effects should be considered when selecting dissimilar materials for the traverse members  20  and extension members  30 .  
         [0041]     In certain embodiments, the attachment members  40  may extend outward from the main body of the traverse member  20 , such as those shown in, for example, the embodiments of  FIGS. 4A, 4E ,  4 I and  4 M, and the traverse member  20  is attached to the extension member  30  at the attachment member  40 . In other embodiments, the attachment members  40  may extend inward from an outer surface of the traverse member  20  towards an inner center of the main body of the traverse member  20 , such as those shown in, for example, the embodiments of  FIGS. 4B, 4F  and  4 J. In still other embodiments, one attachment member  40  may extend outward from the main body of the traverse member  20 , while the other attachment member  40  extends inward, such as those shown in, for example, the embodiments of  FIGS. 4C-4D ,  4 G- 4 H, and  4 K- 4 L.  
         [0042]     There are numerous ways to effectively attach the traverse members  20  to the extension members  30 . Some of the methods of attachment well known to those skilled in the art can include, but are not limited to, welds, screws, rivets, and the like. Attachment of the traverse members  20  to the extension members  30  to form a storage surface assembly is not necessarily limited to a single method of attachment within a single storage surface assembly. A combination of attachment methods may be used in assembling a single storage surface assembly, based on the requirements dictated by a particular application.  
         [0043]     Additionally, with any of the above attachment methods, individual traverse members  20  can be removed from the extension members  30  and replaced with new/repaired traverse members  20  without complete disassembly of the storage surface assembly  100  or replacement of all traverse members  20  while still maintaining the 50% open area. This allows for cost effective repair of the storage surface assembly  100 , and a potentially longer term of use than related art systems.  
         [0044]     In yet another embodiment, the extension members  30  are formed as shown in  FIG. 2D  with a recess  35  which is designed to mate with an end of the traverse member  20  and allow for slidable assembly of the traverse member  20  into the recess  35  of the extension member  30 . In this manner, movement of the traverse member  20  along the extension member  30 , as well as spreading of the traverse member  20  due to a load applied by a storage item is prevented by the sides of the recesses  35  rather than by the attachment member  40 .  
         [0045]     The extension member  30  can also be formed as shown in  FIG. 2E , with slots  36  positioned along a horizontal portion of the extension member  30  and corresponding to the attachment members  40  of the traverse member  30 , allowing for slidable assembly of a single traverse member  20  such as those shown in, for example,  FIGS. 4A-4M , into the slots  36  of the extension member  30 , or a “stack” of traverse members as shown in, for example,  FIGS. 2F-2H , and discussed below. A flat plate  31  is then attached to a bottom surface of the extension member  30 , with the attachment members  40  positioned therebetween, thus securing the traverse members  20  in place.  
         [0046]     The spacing of the slots  36  along the horizontal portion of the extension member  30  may be adapted to meet the requirements of a number of different storage applications, and the slots  36  need not be equally spaced. Additionally, as shown in  FIGS. 2F-2H , the attachment member  40  of a first traverse member  20  can be placed on and aligned with an attachment member  40  of a second traverse member  20 , forming a “stack” of attachment members  40 . The stacked attachment members  40  of the first and second traverse members  20  can then be slidably inserted into the slots  36 . Stacked traverse members  20  need not necessarily have the same cross sectional shape or attachment member  40  orientation. For example, the traverse member  20  shown in  FIG. 4A  can be stacked with any of the traverse members  20  shown in  FIGS. 4B-4M  and then slidably inserted into slot  36 . Likewise, the traverse member  20  shown in  FIG. 4B  can be stacked with any of the traverse members  20  shown in FIGS.  4 A,  4 C- 4 E,  4 G- 4 I, and  4 K- 4 M, and so on.  
         [0047]     Both the single and the stacked slidable attachment methods discussed above may be employed with a variety of different traverse member  20  combinations, and traverse members  20  need not all be of the same shape in a single storage surface assembly.  
         [0048]     A snap fit procedure could also be employed in attaching traverse members to extension members, as shown in  FIGS. 2I-2M .  FIG. 2I  shows a snap fit extension member  32  with a vertical extension  33  formed along its length, and notches  33   a  and  33   b  corresponding to the cross sectional shape of attachment members  23   a  and  23   b  of a snap fit traverse member  23  cut into the vertical extension  33  at predetermined positions along the length of the snap fit extension member  32 . When attachment members  23   a  and  23   b  are aligned with notches  33   a  and  33   b , a downward force applied to the snap fit traverse member  23  would cause the attachment members  23   a  and  23   b  to temporarily contract as they pass through the more narrow portion of the notches  33   a  and  33   b , and return to their original shape once they enter the wider portion of the notches  33   a  and  33   b , thus securing the snap fit traverse member  23  to the snap fit extension member  32 . A similar procedure would be used to snap fit the snap fit traverse member  23  to the snap fit extension member  32  shown in  FIGS. 2J-2L .  
         [0049]      FIG. 2M  shows a snap fit extension member  32  with a vertical extension  33  formed along its length. Notches  33   c  and  33   d  corresponding to the cross sectional shape of attachment members  23   c  and  23   d  of a snap fit traverse member  23  are cut into the vertical extension  33  at predetermined positions along the length of the extension member  32 .  FIG. 2N  shows this snap fit traverse member  23  secured to this snap fit extension member  32 . The notches  33   c  and  33   d  are specifically shaped to accommodate the curved shape of the attachment members  23   c  and  23   d . Each notch includes a protrusion  33   e  which engages a corresponding slot  23   e  formed in the side wall of the snap fit traverse member  23  as the attachment members  23   c  and  23   d  are directed downward into the notches  33   c  and  33   d , thus securing the snap fit traverse member  23  to the extension member  32 , as shown in  FIG. 2N . Although the extension members  32  and traverse members  23  shown in  FIGS. 2M-2N  include two protrusions  33   e  and two corresponding slots  23   e  formed in each end of each traverse member  23 , it is well understood that these elements could also be effectively secured with a single protrusion  33   e  and slot  23   e  at either one end or each end of the traverse member  23 . Other means of attaching the traverse members to the extension member may also be appropriate based on the application, materials used, and other factors which may effect the assembly&#39;s performance.  
         [0050]      FIG. 5  is a top view of a storage surface assembly according to an embodiment of the invention. The storage surface assembly of  FIG. 5  includes a plurality of traverse members  20  extending between two extension members  30 . The traverse members  20  are spaced apart from one another forming open spaces  50 . In  FIG. 5 , the traverse members  20  are shown substantially equally spaced along the extension members  30 . However, the amount of open space  50  between traverse members  20  may be varied as shown in  FIGS. 6A-6B , and various traverse member  20 /open area  50  spacing combinations may be appropriate, based, for example, on the desired configuration and/or application. For example, the traverse members  20  may be grouped, as in the embodiment of  FIG. 6B , with the open space  50  between groups in these alternative configurations adjusted to conform to the open area requirement as necessary. In this manner, the grouping and spacing of traverse members  20  along the extension members  30  may be adjusted to meet individual user requirements without redesign of the base components of the storage surface assembly  100 .  
         [0051]      FIG. 7  is a front view of a rack beam assembly according to an embodiment of the invention incorporating a storage surface assembly according to the invention. The rack beam assembly of  FIG. 7  includes a storage surface assembly  100  installed in a set of rack beams  200 . The tack beams  200 , designed to fit one of many standard commercial/industrial tacking systems, may be specified by the user and are well known in the industry.  FIG. 8  is a perspective view of the tack beam assembly  300 . As shown in  FIG. 8 , the tack beam assembly  300  may be installed in a commercial/industrial racking system  400 .  
         [0052]     As evidenced by the numerous traverse member configurations, attachment methods, and grouping/spacing configurations discussed herein, the various embodiments of the invention provide clear advantages over the related art with an easily and inexpensively manufactured and distributed shelving solution that exhibits adequate load beating capability and structural integrity while still meeting the 50% open area requirement, and which can be easily adapted to meet specific user needs.  
         [0053]     The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the invention. The present teaching can be readily applied to other types of apparatuses. The description of the invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures.