Reinforced and bolted rack truss

A rack truss for use in forming shelf-type storage racks which may be assembled at the site using bolts and/or which includes reinforcement at the lower level of the rack truss.

BACKGROUND OF THE INVENTION

The present inventions relate generally to improved shelf-type storage racks. More particularly, the present inventions relate to rack trusses that are bolted together for ease of shipment and assembly and/or which are reinforced at the bottom to prevent damage to the trusses by, among other things, lift trucks during loading or unloading.

Shelf-type storage racks are well known in the storage and warehouse industries. Such racks typically include at least four columns, two in the front or access aisle and two in the back. Lateral beams interconnect the pairs of front columns and pairs of back columns. The lateral beams, in conjunction with optional cross members between the lateral beams, form shelves used for storage of pallets and their loads. Typically, there is a shelf approximately 48 inches from the ground and then shelves above the lowest shelf spaced approximately every 48 inches, or for other loads at load required increments.

Each pair of front and back columns are provided with transverse support beams that interconnect the front and back columns. Diagonal support braces between the front and back columns may also be provided for increased strength, rigidity and stiffness. Each pair of front and back columns and the associated beams and braces are typically referred to in the industry as rack trusses. Each pair of opposing rack trusses, and their interconnecting lateral beams, form a typical shelf-type storage rack. The racks may be placed side-by-side and/or back-to-back in arrays to form the desired storage rack system.

The components that form the storage rack trusses, such as the transverse supports and diagonal support braces, are typically welded together and painted at the fabrication site and then shipped to the storage facility. For example, the transverse supports and any diagonals are typically welded to the front and back columns to form the rack truss. Once at the storage facility, the lateral beams interconnecting each opposing pair of trusses are installed by welding or bolting (see e.g., U.S. Pat. No. 4,678,091). The bottom of the columns of the rack trusses may be placed directly on the warehouse floor. Because the trusses are fabricated prior to shipping and installation, known rack trusses are somewhat difficult to handle during assembly, take-up more space during shipping and can be difficult to paint.

In use, the pallets and their loads are placed on or removed from the shelves using a fork lift truck. Experience has shown that the bottom portion of the rack truss and particularly, the bottom 4-6 inches of the truss, take the most abuse. For example, the bottom portion of the front columns at the access aisle, are often bumped by pallets or the forks of a lift truck during the placement or removal of pallets and their loads. This can result in, among other things, a weakened rack structure.

SUMMARY OF THE INVENTION

The present inventions preserve the advantages of known storage racks and storage rack trusses and also provide new features and advantages. For example, the present inventions provide storage racks and rack trusses that may be bolted together at the site making shipping and assembly more efficient and/or which provide reinforcement in the lower portion of the truss to resist abuse from forks of fork trucks and the like.

In a preferred embodiment of the present inventions, a bolted truss for use in forming storage racks is provided including at least one front column having an interior face and at least one rear column having an opposing interior face. A plurality of stubs secured to the interior face and flange of the front column and a series of stubs similarly secured to the interior of the rear column, with the stubs on the front and rear columns opposing each other. A preferred embodiment also includes a plurality of transverse beams having a front and back end which are placed between the front and rear columns, the front end of which is bolted to the stub on the front column and the rear end of which is bolted to the opposing stub on the rear column. The stubs and transverse beams may be formed of structural angles. In addition, at least one diagonal brace may also be provided which is attached to the stubs. A preferred embodiment of the present invention may also include a truss reinforcement means.

Another preferred embodiment of the present inventions is a reinforced truss for use in storage racks including at least one front column having an interior face and at least one rear column having an opposing interior face. The preferred embodiment also includes a horizontal locking tab secured to the inside face of the front column and a vertical locking tab spaced rearwardly from said front column; a horizontal locking tab secured to the inside face of the rear column; and, a horizontal stiffening member including a front end and a rear end, having a vertical support leg spaced rearwardly from the front end, the front end of the horizontal stiffening member capable of being bolted to the horizontal locking tab of the front column, and the rear end capable of being bolted to the horizontal locking tab on the rear column, and the vertical support leg capable of being bolted to the vertical locking tab. The preferred embodiment may also include a vertical locking tab on the rear column and a vertical support leg on the rear end of horizontal support leg such that the rear vertical support leg may be bolted to the rear vertical locking tab. This preferred embodiment may also include means for assembling the truss using bolts.

Accordingly, it is an object of the present inventions to provide a rack truss that may be assembled by bolts.

It is another object of the present inventions to provide a rack truss that provides reinforcement of the columns at the lower portion of the truss.

It is an additional object of the present inventions to provide a rack truss that is assembled using bolts and which provides reinforcement of the columns at the lower portion of the truss.

Yet another object of the present inventions is to provide a bolted truss that self-aligns during assembly of the upright portion of the truss.

Yet an additional object of the present inventions is to provide a bolted and/or reinforced rack truss that can be used for drive-in rack systems.

Still another object of the present inventions is to provide a bolted and/or reinforced rack truss that can be used for push-back rack systems.

A further object of the present inventions is to provide a rack truss that is easy to fabricate, paint, ship, assemble and install.

INVENTOR'S DEFINITION OF THE TERMS

The terms used in the claims of this patent are intended to have their broadest meaning consistent with the requirements of law. Where alternative meanings are possible, the broadest meaning is intended. All words used in the claims are intended to be used in the normal, customary usage of grammar and the English language.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Set forth below is a description of what is currently believed to be the preferred embodiments or best representative examples of the inventions claimed. Future and present alternatives and modifications to the embodiments and preferred embodiments are contemplated. Any alternatives or modifications which make insubstantial changes in function, purpose, structure or result are intended to be covered by the claims of this patent.

A preferred embodiment of the bolted truss of the present inventions is shown generally as20inFIG. 1. The preferred components of preferred truss20are shown inFIGS. 1-6and11. A preferred embodiment of the lower truss reinforcement of a bolted truss20is shown generally as50inFIG. 7. Preferred components of preferred lower reinforcement50are shown inFIGS. 7-10. It will be understood by those of skill in the art that bolted truss20inventions may be used alone or in combination with truss reinforcement inventions50. Similarly, truss reinforcement inventions50may be used alone or in combination with the bolted truss20inventions.

By reference toFIGS. 1-6, bolted truss20includes a front column22and a rear column24. A plurality of transverse beams26and diagonal braces30are also provided between front column22and rear column24. In the preferred embodiment, columns22and24are made from structural channels having a web21and flanges23and25. The bottom of front column22may be provided with a foot35and the bottom of rear column24may also be provided with a foot36. Feet35and26may be used to secure truss20to the floor and may also be incorporated into the truss reinforcement50invention, as hereinafter described. It will be understood by those of skill in the art that a wide variety of structural members may be used to practice the present inventions. The above described components are bolted together as hereinafter described to form bolted truss20.

A series of stubs40are provided on the inside face of front column22. Rear column24is also provided with a series of stubs40which are mounted on the opposing inside face of rear column24. As shown inFIGS. 2,5and6, stub40is welded or otherwise secured to the interior of front column22along flange23and web21. Stubs40on rear columns24are similarly mounted. In a preferred embodiment, stubs40are formed from structural angles having a horizontal leg41and a vertical leg42, which is provided with a hole43. The horizontal leg41of stub40is notched44so that it can be securely attached to the inside surface of flange23of column22by welding or other well known means.

Similarly, the interior of rear column24is provided with a series of stubs40that oppose stubs40on front column22. Stubs40on front column22and rear column24are used to secure transverse beams26as well as diagonal braces30, as hereinafter described. Again, it will be understood by those of skill in the art that stubs40may be formed from a wide variety of structural components consistent with the inventions.

Preferred transverse beam26is formed from a structural angle having a vertical leg27and a horizontal leg28. A series of holes29are provided, one in the center and one at each end (seeFIG. 3). Diagonal brace30is also preferably formed from a structural angle. It includes a vertical flange31, a horizontal flange32and three holes33, one at each end and one in the center. The horizontal flange32of each end of brace30has a notch34in the horizontal flange32so that it may be secured to stub40.

As a result of the unique aspects of the present invention, the truss components, such as columns22and24and their associated stubs40, transverse beams26and diagonal brace30may be fabricated and shipped to the site prior to assembly. Once at the site, transverse beams26are installed between front and back columns22and24by bolting one end of transverse beam26to stub40on the front column22through holes43on stub40and holes29at one end of transverse beams26. The other end of transverse beams26is attached to stub40of rear column24in the same way. Preferably, vertical leg42of stub40is parallel to and faces vertical leg27of transverse beams26(seeFIGS. 5 and 6).

Diagonal brace30may be installed on a stub40of front column22and a stub40that is two stubs40higher in on back column24as shown inFIG. 1. One end of diagonal brace30is secured between vertical leg42of stub40and vertical leg27of transverse beam26using a bolt through holes43,33and29of the respective members. Notch34on horizontal flange32of diagonal brace30enables the horizontal flange32to clear the horizontal leg41of stub40. The other end of diagonal brace30is attached to stub40of rear column24in the same manner. The center of diagonal brace30is then attached to the center of the next higher transverse beam26using a bolt through center holes33of diagonal brace30and center holes29of transverse beam26(seeFIG. 1).

In this preferred form of installation and structural components (horizontal flange41of stub40, one end of vertical flange31of diagonal brace30and horizontal flange28of transverse beam26), the entire interior face between flanges23of front and rear columns22and24is filled (see e.g.,FIG. 6). This configuration provides increased strength. It also reduces the potential for twisting of the components.

A preferred alternative to the above arrangement of diagonal brace30is also appropriate and is shown inFIG. 11. In this embodiment, a diagonal brace30is provided diagonally between each pair of transverse beams. For example, one end of diagonal brace30is secured on a stub40of front column22as described above. The other end of diagonal brace30is attached to the next higher stub40of rear column24, also in the same manner as described above. Of course, in this embodiment, there is no need for center holes33of diagonal brace30or center holes29of transverse beam26.

A preferred embodiment of the truss reinforcement50inventions may generally be seen by reference toFIGS. 7-10. Truss reinforcement50includes a stiffening beam51formed from a structural channel having a horizontal web52and two vertical flanges53. A hole54is provided on the front end of stiffening beam51and a hole55is provided on the back end of stiffening beam51to function as hereinafter described. A vertical support leg56is attached to the underside of stiffening beam51generally toward the front of member51. Vertical support leg56is formed from a structural channel member having a web57and two flanges58. A hole59is provided on web57to function as hereinafter described.

The bottom of front column22is provided with a horizontal locking tab60(seeFIG. 8). In a preferred embodiment, horizontal locking tab60is made from a piece of a structural angle having a vertical flange61and a horizontal flange62. Vertical flange61is welded to the inside of web21of front column22between flanges23and25. Horizontal flange62is provided with a hole63that is designed to mate with hole54on the front stiffening member51.

A vertical locking tab64is also provided in association with front column22. Vertical locking tab64may be formed from or attached to front foot35of front column22. Vertical locking tab64includes a hole65that is designed to mate with hole59on web57of vertical support leg56. It will be understood by those of skill in the art that vertical locking tab64is spaced from front column22the same distance as vertical support leg56such that the web57of support leg56mates with vertical locking tab64.

Rear column24is provided with a horizontal locking tab60(seeFIG. 9) that opposes horizontal locking tab60on front column22. The horizontal locking tab60on rear column24also includes a vertical flange61attached to inside web21of front column24and a horizontal flange62. A hole66is provided on horizontal flange62that is designed to align with hole55on the rear end of stiffening beam51.

Horizontal stiffening member51is installed by placing the front end on horizontal locking tab60and bolting them together through holes54of stiffening member51and holes63of horizontal locking tab60. Similarly, the rear end of horizontal stiffening member51is placed on horizontal locking tab60which is then bolted through holes55and66. Vertical support leg56is bolted to vertical locking tab64through its holes65and hole59on the web57of vertical support leg56. In addition to providing extra strength to prevent abuse to the lower front column22, when vertical support leg56is attached to vertical locking tab64, the front22and rear24columns are brought into proper vertical alignment. Thus, the present inventions also provide a means for self-alignment of the truss columns22and24during assembly.

In an alternative embodiment of truss reinforcement50, the lower portion of front column22is provided with the same components as rear column24, as shown inFIG. 9. Specifically, like rear column24, front column22is provided with a horizontal locking tab60having a bolt hole66. In this embodiment, horizontal stiffening member50does not require a vertical support leg58or a vertical locking tab64. Thus, horizontal stiffening member51is installed between the columns22and24and bolted at each end to horizontal locking tab60. This embodiment is particularly useful in, but not limited to, drive-in rack systems.

It will be understood by those of skill in the art that the truss reinforcement inventions50may be practiced using a wide variety of structural members other than the types of members shown in the preferred embodiment. In addition, a vertical support leg56and a vertical locking tab64may be provided on the rear end of stiffening beam51and rear column24. Such an arrangement, while acceptable, is not generally preferred because most of the abuse during loading and unloading occurs to the lower portion of front column22.

The above description is not intended to limit the meaning of the words used in or the scope of the following claims that define the invention. Rather, it is contemplated that future modifications in structure, function or result will exist that are not substantial changes and that all such insubstantial changes in what is claimed are intended to be covered by the claims. Thus, while preferred embodiments of the present inventions have been illustrated and described, it will be understood that changes and modifications can be made without departing from the claimed invention.

Various features of the present inventions are set forth in the following claims.