Abstract:
A rack for producing transport bundles of stacked lumber comprises a deck over which is laid plural rows of dunnage-and-banding gutters. The which dunnage-and-banding gutters are arranged to define a major channel that has a bottom wall extending between spaced sidewalls and is sized to receive dunnage stock. Two by four lumber (4.5 cm by 9 cm) is common for dunnage stock. The dunnage-and-banding gutters also define a minor channel recessed in the major channel&#39;s bottom wall. The minor channel is sized to receive banding material such as strap. Preferably both the dunnage stock as well as the banding can be fed in axially from either open end of the gutters after the lumber has already been stacked up on top.

Description:
CROSS-REFERENCE TO PROVISIONAL APPLICATION(S)  
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/171,712, filed Dec. 22, 1999. 
     
    
     
       BACKGROUND AND SUMMARY OF THE INVENTION  
         [0002]    The invention generally relates to material handling apparatus and more particularly to a rack for producing transport bundles of stacked lumber as well the use of such rack in the production of such bundles. Additional aspects and objects of the invention will be apparent in connection with the discussion further below of preferred embodiments and examples.  
           [0003]    It is an object of the invention to provide a rack for a lumber yard to facilitate producing transport bundles of stacked lumber gotten from a collection of diverse sources.  
           [0004]    It is an alternate object of the invention that the above rack facilitate the successive handling and deposit of the lumber in the stack from any of the successive diverse sources by the heft of a forklift.  
           [0005]    It is another object of the invention that the above rack be provided with structures to facilitate the addition of dunnage and accomplishment of banding during the process of producing and completing a transport bundle of stacked lumber.  
           [0006]    These and other aspects and objects are provided according to the invention by a rack for producing transport bundles of stacked lumber. The rack comprises a frame deck propped up on feet, posts, and gutters as more particularly described below. The frame deck extends between at least spaced lateral members and spaced forward and rearward cross-members. Also, the rack has a pair of upright spaced posts that are mounted to the deck. The posts align in a generally vertical plane that defines a rear margin of the deck.  
           [0007]    Moreover, the rack has plural elongated dunnage-and-banding gutters mounted to extend across the deck generally along a front to back axis. The dunnage-and-banding gutters are arranged to define a major channel that has a bottom wall extending between spaced sidewalls and is sized to receive dunnage stock. The dunnage-and-banding gutters also define a minor channel recessed in the major channel&#39;s bottom wall. The minor channel is sized to receive banding material that relative to the dunnage stock is relatively compact.  
           [0008]    For example, the dunnage-and-banding gutters might be sized such that the major channels accept the axial sliding in of two by four (4.5 cm×9 cm) dunnage stock as the minor channels accept the axial sliding in of flat band material not probably wider than an inch (2.5 cm).  
           [0009]    Given the foregoing, transport bundles of stacked lumber can be built from succesive loads of lumber deposited at successive times on the deck or the top of the stack on the deck by a forklift which preferably approaches from the rear of the rack. To do this, the loads are hefted over the posts and by the occasion of touchdown the forklift&#39;s forks are reaching through the posts. The posts thereafter afford the forklift counteraction against the lumber from shifting rearward as the forklift drags the forks out in reverse. Then, any completed bundle may be banded with or without dunnage and preferably lifted off from the front of the rack.  
           [0010]    Optionally, the dunnage-and-banding gutters may be formed by a pair of opposed angles having spaced base flanges mounted opposite a gap from one another on a planar mounting surface such that the further-apart spaced upright flanges define the major channel&#39;s sidewalls as the co-planar base flanges generally define the major channel&#39;s bottom wall. That way, the gap between the spaced base flanges defines the minor channel.  
           [0011]    The dunnage-and-banding gutters are preferably spaced up off the plane of the deck by a spacing structure which defines the planar mounting surface therefor. Such a spacing structure might be an inverted channel. The dunnage-and-banding gutters might be mounted to cross-members of the deck either for re-positioning or not to vary the number of gutters, the spacing between, as well as how long or short the gutters may be.  
           [0012]    The posts are preferably removably mounted to lateral members of the deck. The posts might include rearward diagonal braces to strengthen how sturdily the posts can oppose a rearward force applied at a given elevation higher than the deck.  
           [0013]    The feet to the deck are given lengths such that the deck occupies a plane either about parallel with the given ground elevation or else is tilted to decline relatively in the rear. The feet may have either a fixed length or are adjustable.  
           [0014]    Additional aspects and objects of the invention will be apparent in connection with the discussion further below of preferred embodiments and examples.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    There are shown in the drawings certain exemplary embodiments of the invention as presently preferred. It should be understood that the invention is not limited to the embodiments disclosed as examples, and is capable of variation within the scope of the appended claims. In the drawings,  
         [0016]    [0016]FIG. 1 is a rear perspective view of a rack in accordance with the invention, for producing transport bundles of stacked lumber;  
         [0017]    [0017]FIG. 2 is a side elevation view of FIG. 1;  
         [0018]    [0018]FIG. 3 is a top plan view of FIG. 2;  
         [0019]    [0019]FIG. 4 is a front elevational view thereof; and,  
         [0020]    [0020]FIG. 5 is an enlarged scale view of DETAIL V in FIG. 4.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0021]    [0021]FIG. 1 is a perspective view of a rack  20  in accordance with the invention, for producing transport bundles of stacked lumber (not shown). In a preferred use environment, the rack  20  is utilized by way of non-limiting example in say wholesale or retail lumber yards. The rack  20  assists in multiple ways the process of the breaking apart of larger bundles of lumber stock, and the production therefrom of a particularized bundle which may be of diverse stock. Such a particularized bundle is likely a particular customer&#39;s order. The trouble of bundling it is undertaken for shipment as by trucking and the like.  
         [0022]    The rack  20  provides more general utility on diverse job sites as a general-purpose lumber stacking apparatus. Diverse example usages and aspects of such use of the rack  20  will be more particularly described further below.  
         [0023]    The rack  20  is preferably constructed very sturdy as the weight of lumber is tremendous in certain cases. For example, if the rack is constructed as a metal frame, it might weigh about 1,000 pounds (455 kg). A heavy frame like this can be moved around the lumber yard or job site or whatever by a forklift (eg., tow motor) or the like, but this is not shown.  
         [0024]    With general reference to FIGS. 1 through 4, the inventive rack  20  comprises a set of removably-connected sub-assemblies  22  and  24 . Each sub-assembly  22  or  24  may be constructed by the fastening, welding or joining together of metal component pieces. These assemblies  22  and  24  comprise a main deck assembly  22  and a pair of post super-assemblies  24  set up on the back edge of the main deck  22 . Each post super-assembly  24  comprises a footing  28 , a post or mast  30  standing upright on the footing  28 , and a brace  32  set an angle between the footing  28  and post  30  to strengthen the mounting of the upstanding post  30 .  
         [0025]    The braces  32  are preferred because they prop the posts  30  in the direction counter to the main applied force that the posts  30  must sustain. That is, a forklift ordinarily will deposit lumber on the deck  22  by approaching the deck  22  from the rear edge. To do this, the forklift must elevate the load all the way above the posts  30  to clear their tops and then deposit the load on the deck  22  by having the forks reaching through the posts  30 . Once this is done, the forklift retracts its forks by reversing such that the posts  30  oppose the lumber from shifting backwards as the forks scrape out from underneath their load. Hence, the braces  32  prop the posts  32  in opposition to the lumber shifting rearwards with the forks while the forks are dragged out from behind in this process.  
         [0026]    Each post  30  and brace  32  is preferably produced from square-tube stock as the footing  28  is preferably produced from flat-plate stock. All are preferably fixed together sufficiently sturdily as by welding or the like. The posts  30  might alternatively be produced with telescoping inner sleeves (not shown). Such telescoping inner sleeves would allows the posts to be given an adjustable greater height in cases when users would desire the extra height. The inner sleeves could be releasably fixed in place by thumb-tab headed set screws or the like twisted into threaded holes for them in the main or outer sleeve  30  (no set screws are shown, nor are inner sleeves).  
         [0027]    The post super-assemblies  24  are preferably removably connected to the main deck assembly (or sub-assembly)  22  by bolts  34  or other like fastening means. For one, easy connection and disconnection allows shipment of the rack  20  in a collapsed position (not shown) such that the rack  20  can be erected and bolted together in the erected position, as shown by the drawings, when the collapsed rack  20  reaches the job site. FIG. 2 shows the preferred mode of connecting the post super-assembly(ies)  24  to the main deck sub-assembly  22  to comprise bolts  34  through the footing  28  of the post super-assembly  24 . For another reason, disconnection and re-connection affords the opportunity to move the post assemblies  24  about on the deck  22 . It is advantageous that the post assemblies  24  can be erected in varying widths apart. This allows workers to change the gap between the posts  30 , perhaps very narrow in some cases or wider in others. To do this, the support rack  20  would likely include a base board (not shown) lapped across and fastened down on the rearward extensions of siderails  40  as above struts  52 . Such a base board (again, not shown) would preferably be pre-formed with bolts holes at given locations allowing incremental adjustment of the width between the post assemblies  24 .  
         [0028]    To turn to the main deck sub-assembly  22 , it comprises four legs  38 . The legs  38  prop up a pair of left and right side rails  40 . Preferably the front legs are a bit longer than the rear legs. That way the deck  22  has a rearward tilt to it. Such a rearward tilt helps keep stacked lumber product leaning into the posts  30  at rest. Also, when a fork lift is reversing itself, dragging its forks from out between layers of stacked lumber, the rearward tilt helps keep the rack  20  standing in its place. That is, the rack  20 &#39;s rear legs  38  ought to dig in the ground. A preferred option is either or both sets of front and back legs  38  are provided with an extensible lower leg (no such lower leg is shown). A way to achieve an extensible lower leg is to produce it out of a threaded rod which terminates in a foot. The bottom of the main leg  38  might be provided with a threaded hole in which the threaded-rod extensible foot twists in. That way, the tilt of the main deck  22  can be adjusted by twisting the threaded lower leg (again, not shown).  
         [0029]    The span between the side rails  40  is fixed by a set of three spaced main deck members  42 . Suspended from each of the front and back deck members  42  are full-width rungs  44 , of which the front rung  44  is more clearly shown by the front elevational view of FIG. 4. The rungs  44  are suspended from each one&#39;s respective deck member  42  by a series of short hangers  46 . The left and right openings  48  defined below the deck members  42  by the rungs  44  and hangers  46  operate as flat passages  48  for the removable insertion and retraction of the forks of a fork-lift and so on (not shown).  
         [0030]    With reference to FIGS. 1 and 2, the rigidity between the legs  38  and side rails  40  is afforded extra support from struts  52  as well as stiffening plate  54 . Each leg  38 , side rail  40 , deck member  42 , rung  44 , hanger  46  and strut  52  is preferably produced from square-tube stock, and all which are preferably fixed together sturdily as by fastening or welding and so on. The stiffening plate  54  is preferably produced from flat-plate stock and is likewise preferably attached sturdily by welding or fastening and the like.  
         [0031]    The main deck members  42  carry on top of themselves a set of spaced dunnage gutters  60 . Three such dunnage gutters  60  are shown. Each extends on axes parallel with the front to back direction. FIG. 5 shows a preferred format of construction of the dunnage gutters  60 . The dunnage gutters  60  are propped up off the main deck members  42  by an inverted channel member  62 . The web of the inverted channel  62  member carries a pair of angles  64  arranged such that the pair of angles  64  provide a pair of spaced base flanges  66  as well as a pair of further-spaced apart upright flanges  68 . The upright flanges  68  cooperatively define the gutter walls for the dunnage gutter  60 . The spacing between the base flanges  66  defines an open way  70  or passage-way for banding material.  
         [0032]    Hence, the upright flanges  68  define a main channel for the nesting or axial sliding in of dunnage such as 2″×4″ runners or the like. In contrast, the much smaller sub-channel  70  defined between the in-turned base flanges  66  defines a banding sub-channel  70  which allows the nesting or axial sliding in of band strapping material. The dunnage gutters  60  are preferably produced from metal stock that allows welding at the weld-zones  72  indicated in FIG. 5.  
         [0033]    Whereas FIG. 5 shows the dunnage gutters  60  welded to the deck member  42 , alternatively the gutters  60  could be attached by fastening such as bolts or the like. The inverted channel piece  62  might be featured with little tabs or ears that lay flat on the deck piece  42  (such ears or tabs are not shown). The ears or tabs would likely be formed with holes for accepting a bolt that inserts through a complementary hole in the deck member  42 . That way, the dunnage gutters  60  can be varied by number in use, the spacing between those put to use, as well as substituting for elongated gutters which might greatly extend beyond the front deck piece  42  in order to give the deck  22  a greater span in the front to back direction for certain applications, say for exceptionally wide panel products or the like (only one length of dunnage gutters  60  are shown).  
         [0034]    Diverse example usages, as well as aspects of such use of the rack  20  include the following. The rack  20  ships in a collapsed condition such that the receiving party assembles the rack  20  in the erect position as for example shown by the drawings when received. This generally entails bolting together the disassembled base and super-assemblies  22  and  24 .  
         [0035]    The upright posts  30  allow a forklift to approach the rack  20  from the rear, elevate the lumber high up over the posts  30  and then deposit and stack the lumber either • on the dunnage gutters  60 , if that is the first deposit on the rack, or • on lower layers of lumber if the current load is just being piled on earlier deposits on the rack  20 . The posts  30  act to obstruct and stabilize the deposited lumber as the forklift drags its forks out from under lumber layers by reversing backwards away from the rack  20 .  
         [0036]    The dunnage gutters  60  are sized to accept two-by-four dunnage therein, as laid on a broad flat side (eg., two-by-fours being roughly equivalent to 5 cm×10 cm). However, the dunnage gutters can be sized as appropriate for whatever sizes most likely to be used by users. Indeed, it is preferred if the gutters  60  are slightly oversized to allow the axial sliding in of dunnage to be accomplished after when the bundle is already stacked up in place on the rack  20 .  
         [0037]    Banding material can be fed through the ways or sub-channels  70  for the banding material. The two-by-four dunnage and the lumber bundle piled up on top can all be strapped together by encircling bands—three for example—spaced on the spacing set by the dunnage gutters  60 . This allows a forklift to approach the rack  20  preferably from the front and remove the bundle as for deposit on a flat bed and delivery thereafter. That is, while the forklift preferably builds a bundle predominantly by approaching the rack  20  from the rear, the forklift preferably removes a completed bundle from the front of the rack  20 .  
         [0038]    The elevation of the dunnage gutters  60  above ground level preferably measures about eighteen inches (45 cm) for the comfort of workers who manually pile and unpile lumber on and off the rack  20 . This height is preferable for limiting the flexion of the back to a relatively powerful and safe position to handle lumber. If a whole lot lower, the workers might have to stoop over to relatively disadvantageous positions.  
         [0039]    The rack  20  is sufficiently sturdy and strong for a forklift to deposit an entire, complete unit of lumber on it. Some units of lumber are so heavy that it might crush a less sturdy design. Nevertheless, the rack  20  is sufficiently sturdy to withstand the weight of heavy bundles. That way, after the heavy bundle has been deposited on the stand, the forklift operator might separate the bundle once there, and remove away upper layers that don&#39;t belong to that particular customer&#39;s order. The forklift operator can countdown from the top of the bundle how many layers he or she needs to go down in order to remove away the proper amount. Additionally, the posts might be labeled with measure indicia to give the forklift operator an external reference.  
         [0040]    Also, the fork passages  48  (see FIG. 4) are spaced to promote stable transport of the rack  20  on a forklift.  
         [0041]    The invention having been disclosed in connection with the foregoing variations and examples, additional variations will now be apparent to persons skilled in the art. The invention is not intended to be limited to the variations specifically mentioned, and accordingly reference should be made to the appended claims rather than the foregoing discussion of preferred examples, to assess the scope of the invention in which exclusive rights are claimed.