Abstract:
The present invention teaches a new apparatus and process for maximizing the storage space in a warehouse while minimizing aisle space. The invention resides in an apparatus comprising a track assembly and a wheeled platform assembly, whereby a wheeled platform and load (pallet+boxes or crates of goods) are placed on a track assembly and roiled deeper into storage, while leaving room for another load to be placed in front. The invention also teaches various improvements on the design that maximize durability accessibility, and safety.

Description:
TECHNICAL FIELD OF THE INVENTION 
       [0001]    The subject of the present invention relates to the field of warehouse storage devices that maximize the storage space in a warehouse or other storage facility. 
       BACKGROUND 
       [0002]    In shipping, items are generally stored in crates or boxes organized in some fashion within a warehouse. For ease of transport, the crates and boxes are often placed on top of a skid, riser, or pallet. The warehouse space is organized into aisles and storage areas, such that any skid, riser, or pallet may be accessed quickly and transported using a fork lift or some other mechanical device with tines to lift these pallets and bring them to a loading area. 
         [0003]    A pallet is a platform, used to store, stack, and ship goods, that consists of top and bottom deck boards and stringers. The top deck is a plane of boards oriented along the width of the pallet. The stringers are few beams oriented perpendicular to the deck boards running along the length of the pallet that make up the middle section of the pallet. The bottom deck is a plane of boards perpendicular to the stringers and oriented along the width of the pallet. The tines of a fork lift enter the middle section of a pallet adjacent the stringers. 
         [0004]    Multiple variations of the standard pallet exist. In a 2 way pallet, the tines of a fork lift can only enter from the front or back of the pallet parallel to the stringers. In a 4 way pallet some notches are added to the stringers so the tines of a fork lift can go through the stringers as well. In a block pallet, an additional set of perpendicular stringers are added for greater stability. Pallets have mostly been made of out of wood, but some consist of more disposable cardboard materials, and others consist of more durable metal materials. 
         [0005]    A skid is simply a pallet without a bottom deck. In a skid, the beams known as stringers in pallets are called runners. Other pallet variants have been created, See U.S. Pat. No. 8,267,263 called a riser deck, but the basic technology of a deck with beams underneath so a fork lift can lift the deck easily is essential within the shipping industry. Standards exist as to physical and mechanical characteristics of these pallets, skids, and riser decks. ISO Standard 6780: Flat Pallets for Intercontinental Materials Handling; ASTM D 1185: Test Methods for Pallets and Related Structures; and ASTM D6253 Treatment and/or Marking of Wood Packaging Materials. 
         [0006]    The problem with these pallets resides in maximizing the storage area, while minimizing aisle space. In order to easily access each pallet, each pallet must be stacked adjacent to an aisle. These aisles have to be made wide enough to fit a full pallet while being moved by a forklift or other mechanical device with tines. 
         [0007]    Pushback tray storage systems can be used in warehouses and other storage facilities to efficiently store loaded pallets. These systems typically include special rolling trays for supporting the pallets, and the trays include wheels that roll along rails on storage racks or frames. Storage space is optimized, by creating racks with a set of rails and trays that may be loaded with pallets, such that the loaded trays can by pushed back along the rails toward the rear of the storage rack. In this manner, pallets may be stored one in front of one another on a storage rack, and several pallets may be loaded and unloaded from a single aisle, thus, minimizing the number of aisles required for forklifts to maneuver throughout a warehouse and maximizing the storage space between the aisles. 
         [0008]    For example, Japanese Patent Publication No. 5-178,211 published on Jul. 20, 1993 to Kiyomi Asada as disclosed in U.S. Pat. No. 6,386,560 describes a cart having a floor disposed over the four wheels of the device, with a handle bar at one end thereof. The upper surface of the floor has tracks disposed therein, for capturing the wheels of another cart for transport and storage of the second cart. Such a dolly assemble could be adapted specifically for some pallets, but would be unfit for mass storage of such pallets. 
         [0009]    Various rack storage systems also exist as described, for example, in U.S. Pat. Nos. 7,140,503, 6,129,223, 5,415,300, and 5,598,934, incorporated herein by reference. For example in some storage racks, the rails are slightly inclined so gravity cause the carts to naturally move from the back of a rack to the front when the front is not being used. A storage rack may include several such levels of inclined rails for storing several pallets vertically. While these systems have been effective, there is a need for improved designs that reduce overall system cost yet increase adaptability of storage areas without having to utilize a specific system of racks or trays adapted to a specific system of pallets. 
       SUMMARY OF INVENTION 
       [0010]    The invention resides in an assembly and method for using said assembly comprising a transportable track and a wheeled platform that makes it possible to increase the space use of a warehouse by increasing the rack density in the warehouse and allowing double or multiple layers of stacking. A base track assembly whose depth is at least double of the pallet&#39;s depth is placed on the floor. A wheeled platform assembly is placed on the base track assembly. The top support and the base are coupled via roller(s) or wheel(s) and rut(s) or rail(s). In operation, a forklift carries a load (a box of goods and a pallet) and places it in the wheeled platform support. Then the operator pushes the load deeper into storage called the deep end of the track (also called “double-deep”). The operator may then obtain another load and place it on the base tack assembly directly. In this way, a rack, shelf, or floor can have two layers of goods. 
         [0011]    In one embodiment, the assembly has transportable track assembly with a front end and a deep end with rut(s) or rail(s) that may be adapted to receive wheels or rollers. The deep end is usually placed in a storage position that is a difficult position to reach. For example, such deep end may be unreachable by a fork lift, or nestled snuggly within a U-shape enclosure created by  5  or more other pallets. The track may be extendable to fit in deeper pallet enclosures of one to four or more pallets deep. 
         [0012]    In one aspect of a preferred embodiment, a track assembly has two ruts running parallel to each other which are spaced evenly apart because the ruts are attached to opposite ends of at least one cross slat. The cross slat may be any structural material such as metal, wood, plastic, ceramic, or a composite. The ruts are also preferably metal, but can be made from any structural material adapted to receive the wheels from a wheeled platform assembly. In another embodiment, the ruts may be made out of a cheaper or lighter material such as wood or plastic, but lined with another material such as metal, hard plastic, or a ceramic insert to prevent wear and tear from the wheel(s). 
         [0013]    In another aspect of a preferred embodiment, one or more anchor members can be used to attach the transportable track assembly to a floor unit, or units stacked on top of each other, or even on a shelf. The anchor member can be a stud, rivet, or nut and bolt, etc. semi-permanently placed in static storage space, and then attached to the track assembly via a simple fastener, notch, or bracket. The track assembly is still easily removable and transportable to different areas of the warehouse, but the anchor member(s) remain static, yet small and unobtrusive. 
         [0014]    In some embodiments, a simple friction member attached to the bottom surface of the track assembly is more desirable. This friction member is most likely rubber to prevent the track assembly from sliding around, but other embodiments are cognizable where friction is caused by a rough surface. 
         [0015]    In some embodiments, the area of the wheeled platform support is smaller than the load&#39;s bottom area (i.e. the pallet&#39;s area). A standard pallet is 40″×48″, and the wheeled platform assembly&#39;s top surface can be smaller or greater in length than the pallet&#39;s length. 
         [0016]    In some embodiments, the rut(s) or rail(s) are slightly inclined, so when the wheeled platform assembly(s) is placed inside, it always rolls toward the aisle. These embodiments provides for easier access to pallets, because they are always as close to the aisle as possible. 
         [0017]    In some embodiments, it is desirable to keep wheeled platform in place. This can be done by adding a notch or bump to the rut(s) or rail(s) of the track assembly. An additional wedge or post can be added to the notch to further prevent the wheeled platform from rolling. 
         [0018]    In another aspect of a preferred embodiment, the wheeled platform assembly has a top surface adapted to be coupled with a pallet, skid, or deck riser. Such coupling may be done with any such fastener such as screws, nails, tacks, Velcro, glue, a friction member, or even a lock and key type mechanism. Four or more wheels are attached to the bottom surface and are evenly spaced apart such that they fit in the above mentioned rut(s) or rail(s). 
         [0019]    Another embodiment recognizes that 4 wheels can easily be replaced by two rollers. Such rollers do not require two ruts, but instead one giant rut, which is essentially just a box that guides the rollers. The rollers could also have grooves and be guided by a plurality of rails. Similarly, another embodiment recognizes the single tank tread like roller seen in U.S. Pat. No. 7,464,997 can be used in place of 4 wheels or two rollers. Again such a roller does not require two ruts, but instead one giant rut, which is essentially just a box that guides the roller. Or the tread could have a plurality of grooves to be guided by rails. 
         [0020]    Whether four or more wheels, two rollers, or a single tank tread roller or a combination of all three the invention recognizes that such wheel members can easily be attached to a motor, thus offering an additional advantage to moving the wheeled platform assembly around. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1A  is a schematic diagram illustrating a top view of a track assembly of an embodiment of this invention. 
           [0022]      FIG. 1B  is a schematic diagram illustrating a side view of the track assembly of an embodiment of this invention. 
           [0023]      FIG. 1C  is a schematic diagram illustrating a cutaway view of the track assembly of an embodiment of this invention from the front. 
           [0024]      FIG. 2A  is a schematic diagram illustrating a side view of a wheeled platform assembly of an embodiment of this invention. 
           [0025]      FIG. 2B  is a schematic diagram illustrating a top view of the wheeled platform assembly of an embodiment of this invention. 
           [0026]      FIG. 3A  is a schematic diagram illustrating a side view of a wheeled platform assembly being placed on a track assembly according to an embodiment of this invention. 
           [0027]      FIG. 3B  is a schematic diagram illustrating a side view of a wheeled platform assembly being pushed along a track assembly according to an embodiment of this invention. 
           [0028]      FIG. 4  is a schematic diagram illustrating a side view of an embodiment of the apparatus with a load on it stacked on another embodiment of the apparatus with a load. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    A problem resides in maximizing the storage space in a warehouse while minimizing aisle space. The current invention resides in an apparatus comprising a transportable track assembly and a wheeled platform assembly that makes it possible to increase storage space by 50-70% in a warehouse. 
         [0030]      FIG. 1A  is a schematic diagram illustrating a top view of a track assembly  101  of an embodiment of this invention. This embodiment has two ruts to guide a wheeled platform assembly (not shown). The ruts have an outer wall  105 , an inner wall  109 , two end walls  103 , and a floor member  107 . These 5 parts can all be a single body or multiple members, based on ease of manufacturing. If the 5 parts are actually a single body then a U shaped grooved is carved out of the material to form the rut. The two ruts are connected via a cross slat  111 . These members can be made of wood and attached with fasteners, but more durable materials such as metals are preferred. Ceramics, plastics and composites work as well for certain embodiments. 
         [0031]    The track assembly can be described as having a front end and a deep end. The deep end is defined by placing an end wall  103  in a position that is a difficult position to reach. For example, the end wall  103  may be unreachable by a fork lift, or the end wall  103  may be within the deepest part of a U-shape enclosure created by 5 or more other pallets. 
         [0032]    The track assembly is preferably 2 pallets long, which defines the lengths of the walls  105 ,  103  and  109 , but the track assembly may be longer depending on need. Furthermore, the track assembly may be extendable to fit in pallet enclosures of two to four or more pallets deep. To do this the creator simply makes the members  105 ,  107  and  109  have extra leaves or sheathed sections. In such an embodiment, the operator can extend the members by adding the extra leaves or by extending the sheathed extender sections. 
         [0033]    The floor member  107  can have bumps that will prevent the wheeled platform assembly from moving too easily. These bumps could be notches in to the floor member or removable members such as humps. These notches or removable members are within the ruts and can be added or removed to steady the wheeled platform assembly(s) in place. 
         [0034]    The floor member  107  can also have a durable sheet, such as steel or a hard plastic, placed along the inside of the rut created by the walls  103 ,  105 , and  109 . This prolongs the life of the track assembly due to wear and tear caused by the rollers or wheels; this also prolongs the life of the wheels and brackets of the wheeled platform assembly. 
         [0035]      FIG. 1B  is a schematic diagram illustrating a side view of the track assembly of an embodiment of this invention. Preferably, the rut members  103 ,  105 ,  107 , and  109  and the slat members  111  are on the same level as each other and attached with fasteners creating a stable base. 
         [0036]    Friction members, such as rubber, can be attached to the bottom of the track assembly  101 , which prevents the track assembly from sliding laterally while in use. Additionally, a notch can be applied to the bottom of the track assembly  101  that hooks in to an anchor member (not shown) that is permanently affixed to the ground or a rack. Another embodiment is adding brackets to the outside of the track assembly such that the brackets can be looped around said anchors. These anchors secure the track member to prevent lateral movement and promote safety. 
         [0037]      FIG. 1C  is a schematic diagram illustrating a cutaway view of the track assembly of an embodiment of this invention from the front. The view shows that members  105  and  109  are raised, so they can hold the wheels or rollers of a wheeled platform assembly (not shown). The walls  103 ,  105 , and  109  are preferably raised above the floor member  107  forming a rut, but another embodiment has  107  raised instead. In this embodiment  107  is considered a rail. Rails can be any extruded shape and are typically made of metal or another durable material. 
         [0038]      FIG. 2A  is a schematic diagram illustrating a side view of a wheeled platform assembly of an embodiment of this invention. The embodiment shows two width members  205 , and a length member  207 . The area of the top support created by  205  and  207  can be smaller than the load&#39;s bottom area (i.e. the pallet&#39;s area). A standard pallet is 40″×48″, and the length member can be much smaller than that size. 
         [0039]    In some embodiments, a base member (not shown) provides a strong body for the wheel brackets and top members  205  and  207  to attach. This figure shows the width members  205  attached to wheels  211  through wheel brackets  209 . The brackets can hold an axel (not shown) or simply attach to each wheel independently. 
         [0040]    In the rail embodiments of the invention, the wheels  211  need to be beveled or grooved to couple to the rails. This provides for more stable movement, and a strong connection between the rails and the wheels. 
         [0041]    Other embodiments (not shown) have only two rollers instead of four wheels  211 , which does not require two ruts as depicted in  FIG. 1A , but instead one giant rut, which is essentially just a box of outside walls  105  that guides the rollers. The rollers could also have grooves and be guided by a plurality of rails. Similarly, another embodiment recognizes the single tank tread like roller seen in U.S. Pat. No. 7,464,997 can be used in place of 4 wheels or two rollers. Again such a roller does not require two ruts, but instead one giant rut, which is essentially just a box that guides the roller. Or the tread could have a plurality of grooves to be guided by rails. 
         [0042]    In an embodiment not shown a motor could be operably attached to the wheels (or rollers or tank tread) and affixed to the brackets  209  or even an additional base member (not shown). 
         [0043]      FIG. 2B  is a schematic diagram illustrating a top view of the wheeled platform assembly of an embodiment of this invention. The top surface of the wheeled platform assembly is comprised of the length member  207  and the width members  205 . If a pallet is placed on top of this surface, then the bottom deck will be flush with the tops of both the  205  and  207  members. However, if a skid or riser is placed on this assembly, the stringers will rest mostly on the width members  205  and run parallel to the length member  207 . 
         [0044]      FIG. 3A  is a schematic diagram illustrating a side view of a wheeled platform assembly  201  being placed on a track assembly  101  according to an embodiment of this invention. In one embodiment, the assembly has a wheeled platform coupled to a pallet, skid or deck riser. A forklift driver can carry the loaded pallet, skid or deck riser, and position the pallet into the transportable track assembly as indicated by the arrow. This step does not have to be done by a fork lift; placing may be done using any mechanical or motorized device with tines to carry a loaded pallet, and position the pallet into the transportable track assembly. 
         [0045]      FIG. 3B  is a schematic diagram illustrating a side view of a wheeled platform assembly  201  being pushed along a track assembly  101  according to an embodiment of this invention. Once the wheeled platform assembly  201  is placed on the track assembly  101  they are effectively coupled. Due to the wheel-rut coupling, the load laid on the top can be slid from one end to the other end as indicated by the arrows. The load should be pushed to a deeper position. As previously noted bumps or notches may be added to the track assembly  101  to form locked in stable zones to prevent the load from freely travelling from the deep end to the front end (as indicated by the arrows) and possibly hit other loads. Additionally, a slight incline toward the front end may be added to make it easier to retrieve loads that have been pushed to the deep end. 
         [0046]    Once a load has been pushed back to the deep end, a second load may be added to the front of the track. This load could be attached to another wheeled platform assembly (not shown), or simply placed directly on the track assembly  101 . 
         [0047]      FIG. 4  is a schematic diagram illustrating a side view cut away of a metal frame  301  and shelves  313  holding four loads (box of goods  311 +pallet  309 ) on only two embodiments of the invention  307 . The left side of the figure represents deeper storage or the deep end, and the right side represents the front end, which is nearer to an aisle. The top shelf has two sets of goods  311  stacked on pallets  309 . The load on the deep end is on both the wheeled platform assembly  305  and the track assembly  303  portion of the apparatus  307 . One load is on the front end is only on the track assembly  303  of the same apparatus  307 . Below the top shelf is another set of goods  311  and pallets  309  on another embodiment of the apparatus  307 , stacked on another shelf  311 . 
         [0048]    In operation, a forklift carries a load (a box of goods  311  and a pallet  309 ) and places it on the wheeled platform assembly  305  on the right side, and an operator pushes the load to the deep end (also called “double-deep”). Then, the fork lift carries another load and places it directly on the track assembly  303 . In this way, both the deep end and the front end of a rack can have goods. 
         [0049]    In some embodiments of the invention, multiple track assemblies are placed and spaced out periodically down the width of the rack (going in to the page of  FIG. 4 ). These embodiments can be spaced using an extra member in between each track assembly or simply anchoring each apparatus to the rack. 
         [0050]    One skilled in the art will further appreciate the features and combinations from the above described embodiments. Accordingly, the invention should not be limited by what has been particularly shown and described, unless indicated by the claims.