Abstract:
The present invention features a universal, low profile, expandable flow track system that can be drop-load mounted to almost any supporting frame or pallet rack. The flow track system of the invention features a flow track that mounts flush with its end supports, and is infinitely adjustable along both the horizontal axis and depth axis of the storage frame. The flow track is quickly assembled to, adjusted upon, and removed from, the storage frame.

Description:
RELATED PATENTS 
     This application is related to U.S. Pat. No. 5,474,412, issued Dec. 12, 1995, for FLOW RACK SYSTEM. 
     FIELD OF THE INVENTION 
     The present invention pertains to material storage tracks and, more particularly, to an improved, extendable flow track storage system that is universally adaptable to, and infinitely adjustable about, most skeletal storage frames, with the aid of universal retaining elements. 
     BACKGROUND OF THE INVENTION 
     The above-identified U.S. Pat. No. 5,474,412 relates to a new flow track storage apparatus that is adjustable in all three orthogonal planes. The flow track component of the apparatus was designed to seat within a toothed retainer bar that mechanically mounts to the horizontal end supports of a warehouse pallet rack. The flow track is horizontally adjustable along the entire retainer bar and, hence, along the entire horizontal dimension of the pallet rack. This is accomplished by seating the flow track within particular retainer bar slots. The flow track is most welcome for its capability of supporting heavy loads of up to 50 pounds per foot. 
     The aforementioned flow track is vastly superior to conventional, flimsy, poorly supportive rails containing a series of plastic wheels or rollers. These prior art, commonly used rails could never properly support heavy loads, even with heavy, mid-support bracing. The rails were never practical, despite their low cost, which was essentially their only appeal. Lifetime guarantees are commercially offered as an incentive to overlook the inability of the conventional rail system to provide good operability. Therefore, the economy that is originally perceived with this system is, in actuality, deceptive. Their frequent replacement more than counterbalances any initial savings. 
     The above-mentioned flow track system, on the other hand, was well received by the industry, but four major disadvantages remained: (1) it required horizontal toothed retainer bars; (2) the retainer bars required mechanical attachment to the frame, which was both laboriously expensive and time consuming; (3) the flow track system had no facility to extend itself in depth beyond a single frame support; and (4) the flow tracks had a high profile. In fact, they stood several inches above the support beam when they were mounted upon the tier. This seriously reduced the tier density and the vertical storage space. 
     In addition, the horizontal support bars were several inches thick. Top surface mounting of track members on top of support beams meant that several additional inches of vertical space in each tier were wasted. Averaged over many tiers of storage throughout the facility, this high profile method of support wasted space and resulted in a sizable loss of storage capacity. Considering that the object of any storage scheme is to provide high-density storage within a facility, it was obvious that the flow track of the aforementioned patent was not a complete solution to efficiently storing materials in maximum storage facilities. 
     The present invention incorporates an improved flow track system, wherein the flow track component can now be mounted flush with the horizontal support bars via the use of a universal, drop-in retaining element. The universal retaining element allows the track to be drop-loaded upon the beam supports of the frame without tooling or mechanical attachment. Most important, however, is the fact that the new universal end supports can accommodate the new system to most, if not all, skeletal frames and pallet rack tiers. 
     The new system features a placement continuum. The flow track can be adjusted continuously along the entire horizontal plane. More importantly, the new retaining elements allow for the track system to be extended to subsequent support frames, thereby providing sequential extension. No system had ever furnished this capability. Considering that the system is capable of sustained, heavy duty loading of  50  lbs./ft., the invention has produced a remarkable improvement over the prior art. 
     The objectives required of a good flow track system can be enumerated in order of importance, as follows: 
     1) The system must be inexpensive. 
     2) It should be of a low profile design, and work within the side profile clearances of the supporting beam structure, in order to provide maximum storage and cube use. 
     3) It should require minimal assembly. 
     4) The system should furnish the requisite structural support to carry heavy loads. 
     5) It should have a long operative life. 
     6) The system should have adjustability, so as to adapt to changing storage needs. 
     7) The system should be adaptable to the majority of warehouse and storage facilities. 
     8) The system should provide the capability to extend the tracks in the depth axis to subsequent storage frames, and to extend the tracks along the horizontal axis to fill the entire width of each storage tier. 
     The current invention not only provides all of the necessary aforementioned requirements of a good flow track system, but it also eliminates all of the previous drawbacks of its predecessor design. In this regard, it has advanced the state of the art by its universal adaptability to most warehouse facilities. 
     The improved flow track system of this invention can be drop-loaded upon the support beams of the frame assembly, thus providing convenience of assembly. The flow track member can be placed flush with the end supports in any position along the horizontal plane. The end of the flow track can also be positioned below the end supports, so that the end support can act as a limit stop for the stored materials. The improved flow track can provide heavy duty support and superior flow of materials over greatly extended distances along both the horizontal and depth axes. 
     The current invention features and facilitates at least four major functions: 
     1. It can be drop-loaded onto a storage tier. 
     2. It is infinitely expandable along the horizontal and depth axes of any tier of a storage facility. 
     3. It has a low profile and is substantially flush mounted to a support beam of a storage tier. 
     4. It has universality for adoption to almost any storage frame or storage system. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, there is provided a universal flow rack system that can be fixtured to almost any supporting frame of a storage system without tools. The flow rack system of the invention features a flow track which has a roller conveying surface. The flow track comprises two elongated side rails that rotatably support a series of periodic, elongated, spaced-apart rollers therebetween. The flow track is fitted with stand members fixedly disposed across the elongated side rails at each distal end. The stand members are substantially parallel to the rollers and are designed to add bracing to the ends of the elongated, side rails. The stand members are also designed to function as supporting members, so that the flow track can be adjustably attached to the supporting frame of a pallet rack and provide a low profile. 
     The flow track is also movably attached to the storage frame by means of a hanger member. The hanger member comprises a hooked section on one end and a U-shaped support bracket section on the other end. The support bracket of the hanger member is designed to be placed below one of the stand members and to act as its support. Each respective stand member rests on the U-shaped support bracket section, so that the hanger member carries the distal end of the flow track. 
     The hooked section of the hanger member is designed to fit over a standard end support of a storage frame, thus attaching the flow track to the end support. This allows for quick assembly and removal of the flow track at any time. The flow track is infinitely positionable about the storage frame anywhere along the horizontal axis of the frame, by horizontally moving the hooked section of the hanger member across the span of the end support. The flow track can include an upper and lower stand member on each distal end. 
     The U-shaped bracket of the hanger member can fit under either the upper or lower stand member, thus allowing the flow track to attain a respective flush, or recessed, position with respect to the end support. The end support of the frame acts as a limit stop where the flow track is recessed below the end support. Materials flowing along the declined flow track abut against the end support, and are prevented from falling off the end of the storage frame. 
     The flow track of this invention is easily extendable to subsequent support frames by means of a mid-section, drop-in, retaining element that features a U-shaped channel that rests upon a mid-span support beam. The U-shaped channel has integral, right and left support bracket members that respectively support the back section of a subsequent flow track and the front section of a previous flow track. 
     The flow track system of this invention features three simple parts: (1) a flow track conveyor having a span of about eight to ten feet; (2) a hanger member that supports one end of the flow track, and that movably attaches to the end support of the pallet rack frame; and (3) a mid-span retaining element that drops in, and rests upon, a mid-span support beam. 
     For the purpose of definition, the term “end support” can refer to any end beam member of a tier of a storage frame, such as a pallet or form beam, and the term “mid-span support” can refer to any mid-section or mid-span beam or support member. Moreover, the term “low profile” refers to a flow track that provides a superior vertical storage density. 
     Each tier of the storage frame can be fitted with one or more of the flow tracks along the horizontal (X-axis) width thereof, as befits the need for support of the particular loads being conveyed, as well as a number of extension spans along the horizontal depth (Y-axis). In this fashion, the flow track system of this invention can be extended and custom-designed for all of the needs of almost any storage facility. The heavy duty flow tracks of this invention are strong and provide a long operative life, despite their low cost. The drop-in loading of all parts, retaining and track elements offers unprecedented convenience. The flow tracks of this invention are the first heavy duty extendable flow tracks to the best of our knowledge. 
     It is an object of this invention to provide an improved flow track system. 
     It is another object of the invention to provide a flow track system that is universally adaptable to almost any support frame. 
     It is still another object of this invention to provide a flow track system that provides almost instantaneous assembly. 
     It is a further object of the invention to provide a flow track system of low cost. 
     It is yet a further object of this invention to provide a flow track conveying and storage system that is easily adjustable and that can be secured upon a storage frame or pallet rack without the need for tools. 
     It is still another object of the invention to provide a system that requires neither the purchase nor the installation of specific framework, towers or beams, a system that can be universally installed in almost any currently marketed pallet rack or wide-span rack structure. 
     It is yet a further object of this invention to provide a universal flow track system capable of extension in a depth dimension of the pallet rack tier. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent detailed description, in which: 
     FIG. 1 illustrates a side view of a typical tier-type storage frame commonly found in warehouses and other material storage facilities with the flow track of this invention disposed across its span; 
     FIG. 2 depicts a front view of the storage frame illustrated in FIG. 1; 
     FIG. 3 shows a perspective, in situ view of the flow track system of this invention, with a plurality of flow tracks each with distal end hanger members that mount the flow tracks upon the end supports of the typical storage frame illustrated in FIGS. 1 and 2; 
     FIG. 4 illustrates an enlarged, assembly view of one end of a typical flow track shown in FIG. 3; 
     FIG. 5 depicts an enlarged, sectional view of the flow track and hanger member combination of the flow track system of this invention, as shown in FIGS. 3 and 4, with the U-shaped support section of the hanger member carrying a lower support shaft of the flow track; 
     FIG. 6 shows an enlarged, sectional view of the flow track and hanger member combination of the flow track system of this invention, as illustrated in FIGS. 3 and 4, with the U-shaped support section of the hanger member carrying an upper support shaft of the flow track; 
     FIG. 7 illustrates a perspective view of an extended flow track system wherein a mid-span beam and hanger element supports two back-to-back flow tracks, and a front slide extension member attached to a front support beam; 
     FIG. 8 depicts a perspective, exploded view of the extended flow track system, shown in FIG. 7; 
     FIG. 9 shows a side, exploded view of the extended flow track system, depicted in FIG. 8; 
     FIGS. 9a through 9c illustrate enlarged side views of the retaining hanger elements used to attach the flow tracks and the front slide extension to the support beams for the extended flow track system depicted in FIGS. 7,  8 , and  9 ; and 
     FIGS.  9 aa through  9 cc show further enlarged, detail side views of the retaining hanger elements illustrated in FIGS.  9 a through  9 c. 
    
    
     For the sake of brevity and clarity, like elements and components throughout the following detailed description shall bear identical designations in the FIGURES. 
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Generally speaking, the invention features a flow track comprising a plurality of periodically-spaced rollers, upon which materials can be conveyed from one position to another on the span. The rollers are rotatively supported between two rails or channels defining the flow track. The flow track is positionable between two end support beams of a storage frame or pallet rack, with each end support beam supporting a distal end of the flow track. The flow track is adjustably positionable along the entire horizontal length of the respective end support beams. A movable hanger member supports the flow track for adjustment about the end support beams, and is movable in a horizontal direction (along the X-axis or the longitudinal length of the support beams) with respect to the storage frame or pallet rack. An extended flow track system is achieved in the depth or material flow direction (Y-axis) by use of an alternate hanger member at mid-span. A front slide member is attachable to the front support member using the alternate hanger member. 
     Now referring to FIGS. 1 and 2, a typical tier-type storage frame  10  found in warehouses and other material storage facilities is shown in respective side and front views. This type of storage frame can accommodate the flow track system of the present invention. The frame  10  comprises vertical support members  11  and horizontal end support beams  12 , also known as form bars. The flow tracks  14  of the invention are shown in situ, as they span across the storage frame  10  between the end support beams  12 . The end support beams  12  can support a number of flow tracks  14  on each tier, as illustrated in FIG.  2 . Boxes  15  and other materials are carried by the flow tracks  14  in each tier, as illustrated. Diagonal braces  17  can be used, structurally, to enhance the rigidity of the storage frame  10 , as shown in FIG.  1 . The flow tracks  14  are secured to the end support beams  12  by means of hangers  20 , as is explained hereinafter. 
     Referring to FIG. 3, a perspective view of a plurality of flow tracks  14  of this invention is shown disposed on the end support beams  12  of the storage frame. The flow track  14  is supported on the support end bars  12  by means of hangers  20 , which are shown in greater detail in FIG.  4 . Each flow track  14  comprises a series of spaced-apart, periodically disposed rollers  19 , upon which the boxes  15  are caused to flow (see arrow  25 , FIG.  1 ). The rollers  19  are rotatably fixed upon the flow track  14  and are supported by spaced-apart side rails  24 . Each flow track  14  comprises at least one stand member  21 A and/or  21 B (FIG. 4) that is mechanically fastened between the side rails  24  at each distal end  22 . The stand member  21 A,  21 B can comprise a metal shaft, or rod, that lends added bracing for the side rails  24 . The main purpose of the stand member  21 , however, is to act as an intermediate support member between the flow track  14  and the hanger  20 . The stand member  21  nests within the U-shaped well  26  of the hanger  20 , and is supported thereby, as illustrated by arrows  23 . The distal end  22  of the flow track  14  can accommodate an upper stand member  21 A, shown in solid line at position A, and/or a lower stand member  21 B, shown in phantom at position B. Either upper or lower stand member  21  can be placed within the U-shaped well  26  of the hanger  20 . The purpose of having lower and/or upper stand members  21  at each end  22  of the flow track  14  is explained in more detail hereinafter, with reference to FIGS. 5 and 6. 
     The hanger  20  has a hook section  27  that is shaped to conform to the stepwise configuration  28  of the end support beam  12 . The hook section  27  is placed over the stepwise configuration  28  of the end support beam  12 , as shown by arrows  29 . In this position, the hanger  20  affixes the flow track  14  to the end support beam  12 , via stand member  21 , which is affixed between the side rails  24 , and supported in well  26  of the hanger  20 . The hook section  27  of hanger  20  can be placed anywhere along the horizontal axis C-C of the end support beam  12 , as shown by arrows  32 . In this manner, the positional adjustment of the flow track  14  with respect to the end support beam  12  is infinite. 
     Referring to FIG. 5, the front end  22  of the flow track  14  is shown in enlarged detail. It will be observed that the lower stand member  21 B of flow track  14  rests within well  26  of hanger  20 . In this position, the stand member  21 B rests in well  26 , which causes the top  39  of the flow track  14  to be flush with the top  40  of the end support beam  12 . Packages or boxes  15  (FIG. 1) easily slide over the top  40  of the end support beam  12 , contact the top  39  of the flow track  14 , and flow toward the rear of the flow track, as shown by arrow  25  (FIG.  1 ). 
     Referring to FIG. 6, the rear end  22  of the flow track  14  is shown in enlarged detail. It will be observed that the upper stand member  21 A of flow track  14  rests within well  26  of hanger  20 . In this position, the stand member  21 A rests in well  26 , which causes the top  39  of the flow track  14  to be under-hung from the top  40  of the end support beam  12 . Packages or boxes  15  (FIG. 1) entering the flow track  14  (FIG. 5) easily slide over the flow track  14 , and are stopped by the side  18  of the end support beam  12 , which acts as a stop for the moving package or box  15  (FIG. 1) flowing toward the rear end  22 . 
     The well  26  of the hanger  20  is provided with a triangular reinforcement member  38  in order to stiffen the hanger  20  for accommodating heavy loads. 
     The hook section  27  is also provided with two tabs  34  that form a slot  36 . The slot  36  can be filled with a name plate or name card to mark the materials or contents of the boxes  15  being held upon the flow track support. 
     Referring to FIGS. 7,  8 , and  9 , an extended flow track system of this invention is shown. An extended system is defined by a plurality of flow tracks  14  that is arranged in tandem, or back-to-back along the depth (Y-axis) of the pallet rack tier (FIG.  8 ). Any number of flow tracks  14  can be strung along the Y-axis, as befits the warehouse design. The extended flow track system comprises the usual flow track elements  14  that are drop-loaded (arrows  50 ) onto appropriate retaining elements  20  and  20 ′, which are also drop-loaded (arrows  52 ) onto their respective frame support beams  12 ,  43 , and  43 . A front slide member  45  can be attached to a front loaded retaining element  20 ′, as is explained in detail hereinafter with reference to FIGS.  9 c and  9 cc. 
     Naturally, the number of flow tracks  14  that can be accommodated along the longitudinal length of the horizontal support beams  12 ,  43 , and  43  is dependent upon the span of the vertical frame support columns  11 . In order to provide an extended system in the depth (Y-axis) direction, it is necessary to provide horizontal beam supports  43  mid-span, and in front of the frame support, as shown. It is also necessary to provide an alternate embodiment of the retainer  20 , now shown as channel  20 ′. Channel  20 ′ is provided with a U-shaped hook section  27 ′, as illustrated in FIGS. 9b,  9 bb,  9 c, and  9 cc, respectively. The U-shaped hook section  27 ′ is designed to fit over the horizontal support beams  43 . The back of the extended flow track system (FIGS.  9 a and  9 aa) is supported by the retainer  20  and form beam  12 , as previously described with respect to FIG.  5 . 
     Referring to FIGS.  9 b and  9 bb, the mid-span support arrangement is shown in greater detail. The mid-span comprises the retainer element  20 ′ whose hook section  27 ′ is drop-loaded upon mid-span support beam  42 , as aforementioned. The hook section  27 ′ comprises a left bracket  38 a and a right bracket  38 b. The front end  22  of the tandemly placed flow track  14  is shown in enlarged detail. It will be observed that the lower stand member  21 B of the rear flow track  14  rests within well  26 ′ of the bracket  38 a of hanger  20 ′. In this position, the stand member  21 B rests in well  26 ′, which causes the top  39  of the flow track  14  to be positioned slightly above the top of the mid-span hook section  27 ′. Packages or boxes  15  (FIG. 1) easily slide over the top of the end support beam  43  and flow toward the rear  35  of the front flow track  14 , as shown by material flow arrow  25 . (Also see FIG. 1.) 
     A stop abutment  42 , projecting upwardly from the bottom of well  26 ′, ensures that the stand member  21 B is spaced a given gap distance  44  from the mid-span support beam  43 . This gap distance  44  assures that the front roller  19 a will not abut against the hook section  27 ′, which would hinder its ability to turn. The stand member  21 B of the rear  35  of the front flow track  14  rests in well  26  of the bracket  38 b. 
     Referring to FIGS.  9 c and  9 cc, it will be observed that the alternate retainer element  20 ′ is used for supporting the front end  22  of the front flow track  14 . As before, the stand member  21 B of the front flow track  14  rests in well  26 ′ of the bracket  38 b, and abutment  42  provides a gap  44  to ensure that the front roller  19 a will not abut against the hook section  27 ′, and hence will remain free rolling. The front bracket  38 b allows for the placement of a front slide member  45 , which rests on the well surface  26 . The front slide member  45  has a slide surface  53  that is disposed at a greater angle of decline than that of the flow tracks, in order to facilitate removal of the front container that has slid forward (arrow  25 ) upon the flow track system of this invention. 
     It should be understood that the flow track system of this invention is depth direction (Y-axis) expandable for as many conveying flow tracks  14  as is feasible within the design parameters of the warehouse engineer. 
     Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention. 
     Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.