Abstract:
A flow bay assembly includes a plurality of laterally spaced apart deck modules which may be longitudinally elongated. A plurality of flow rails are provided, each between a pair of deck modules. A plurality of connecting members connect adjacent deck modules and support the flow rails.

Description:
REFERENCE TO RELATED APPLICATION 
     This non-provisional application is based upon U.S. provisional patent application Serial No. 60/077,730, filed Mar. 12, 1998, and claims its priority date from that application, which is hereby incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates generally to material handling systems and, more particularly, to gravity conveying systems, namely flow bays. 
     A flow bay is an area filled with a series of parallel gravity conveying rails, known as flow rails, which are spaced apart and usually arranged in lanes. The lanes may be fed from a perpendicular feed conveyor and typically terminate in a loading dock or other destination point. In this manner, boxed or crated goods, typically relatively large in size, such as appliances, furniture, cabinets, and the like, can be manually transported down one of the lanes of the flow bay by a slight manual push. 
     Conventionally, such flow bays have been manufactured by erecting a series of lateral support beams on the subsurface and attaching the flow rails to the support beams such as by clamping or welding. The area between the flow rails is typically provided with a walking surface made up of plywood sheets which is also supported by the cross members. 
     The difficulty with the known flow bay construction technique is primarily that it is extremely labor-intensive to erect. Often, it is necessary to replace a previous flow bay during a plant shutdown period, which may be a relatively short period, such as three or four days. This is necessary in order to have the flow bay operational again after the shutdown. Because of the labor intensity in erecting the prior known flow bays, it has been extremely difficult to erect an entire flow bay in a relatively short period of time. Additionally, the support surfaces of such prior flow bays, while accommodating the movement of persons on the plywood support surfaces, were not necessarily safe. When a fluid is spilled on such surface, it could result in the surface becoming slippery, thus possibly contributing to a fall. Furthermore, the human support surface was significantly below the flow rails which made lateral movement along the flow bay difficult at best. 
     SUMMARY OF THE INVENTION 
     The present invention provides a flow bay assembly which is exceptionally easy to erect thereby allowing an entire flow bay area to be installed in a relatively short period of time. Furthermore, a flow bay assembly, according to the invention, is exceptionally functional in operation, especially in providing safe movement of persons in the area. 
     A flow bay assembly, according to an aspect of the invention, includes a plurality of spaced apart deck modules and a plurality of flow rails. Each of the flow rails is between a pair of deck modules. A plurality of connecting members connect adjacent deck modules and support the flow rails. 
     According to another aspect of the invention, a plurality of elongated deck modules are laterally positioned and configured to define flow rail supporting surfaces between adjacent deck modules. Adjacent deck modules may be interconnected by slip-lock fasteners which assemble adjacent modules without the necessity for tools. 
     A flow bay assembly, according to the invention, can be interconnected without the necessity for bolting or welding of members together. The deck modules may be configured to be adjustable to a proper orientation from above the deck surface thereby further facilitating ease of assembly. The deck modules are preferably made from steel and provided with an anti-skid upper surface to thereby promote safety in operation. Furthermore, the components making up the flow bay assembly may be manufactured off-site thereby reducing labor costs and further facilitating ease of assembly on the job site. 
     These and other objects, advantages and features of this invention will become apparent upon review of the following specification in conjunction with the drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top plan view of a flow bay assembly, according to the invention; 
     FIG. 2 is a sectional view taken along the lines II—II in FIG. 1; 
     FIG. 3 is a side elevation of a deck module; 
     FIG. 4 is a top plan view of the deck module in FIG. 3; 
     FIG. 5 is an exploded end elevation of a deck module and connecting member; 
     FIG. 6 is a top plan view of a portion of the leveling assembly; 
     FIG. 7 is a sectional view taken along the lines VII—VII in FIG. 6; 
     FIG. 8 is a connecting key, according to the invention; 
     FIG. 9 is an end elevation of an end deck module; 
     FIG. 10 is a bracket useful in FIG. 9; 
     FIG. 11 is an alternative embodiment of a flow bay assembly, according to the invention; and 
     FIG. 12 is another alternative embodiment of a flow bay assembly, according to the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now specifically to the drawings, and the illustrative embodiments depicted therein, a flow bay assembly  20  is made up of a plurality of flow lines designated in FIG. 1 by numbers  47 ,  48 ,  49  . . . , each of which is made up of a pair of flow rails  22  separated by a deck  24 . Deck  24  is established by a series of deck modules  26 . As is understood by the skilled artisan, a flow bay typically has a slight grade from right to left or left to right, as illustrated in FIG. 1, whereby an article can be easily moved along a pair of flow rails by manual force. The deck  24  provides a surface for walking about the flow bay. 
     Each deck module  26  is generally channel-shaped in a lateral cross section, such as illustrated in FIG. 2, and preferably elongated in a longitudinal direction, as best illustrated in FIG.  1 . Each deck module  26  has typically four leveling legs  28  which support the respective deck module with feet  29  which engage a subjacent surface (not shown). Connecting members, such as keys  30 , interconnect adjacent deck modules in order to provide stability to the flow bay assembly. Advantageously, keys  30  additionally vertically support flow rails  22 . In this manner, the flow bay assembly may be readily assembled without the necessity for bolting or welding of the various members. In the embodiment illustrated in FIG. 2, the leveling legs  28  are extended in order to provide a space  32  under the deck modules in order to allow running of a heat duct  34 , electrical conduit  36 , and other utilities. Alternatively, leveling legs  28  could be significantly shorter thereby placing the deck modules closer to the support surface below. 
     As illustrated in FIG. 3, each deck module  26  includes a plurality of slots  38  which accommodate keys  30 . The portion of deck  24  defined by each module is preferably provided with a series of surface features  40  configured to provide an anti-skid characteristic to the deck. Each deck module additionally includes a nut plate  42  including a pair of nuts  43  which threadably receives leveling legs  28 , as illustrated in FIG.  3 . Each leveling leg  28  has an upper end  44  which is configured to receive a tool. In the illustrated embodiment, upper end  44  is slotted in order to receive a screwdriver. Alternatively, it could be hex-shaped to receive a socket wrench or other configuration which would be apparent to the skilled artisan. A through-opening  46  is provided in deck  24  above each leveling leg  28 . This allows the leveling legs to be adjusted from above the deck  24 . This feature allows all of the deck modules to be assembled and subsequently leveled because access under the modules is not required. 
     When a flow rail  22  must be supported at an end of deck module  26  that does not have an adjacent deck module, an offset support bracket  48  is positioned in slot  38  along with key  30  in order to provide support for the flow rail  22 , as illustrated in FIGS. 9 and 10. Flow rail  22 , in the illustrated embodiment, is a single-wheel gravity conveyor with 2-inch diameter wheels on either 3-inch or 4-inch centers of the type marketed by Mannesmann Dematic Rapistan Corp. of Grand Rapids, Mich. under Model No. FTH 30-2. 
     The present invention provides a flow bay assembly which is exceptionally functional. The flow bay assembly can be manufactured in a factory away from the job site and easily assembled on the job site. This is facilitated by the deck modules being readily interconnectable without the necessity for bolting or welding. The deck modules can advantageously be leveled from above the deck surface. The modules are preferably manufactured preferably from steel and imparted with an anti-skid surface. This provides a strong and safe assembly. Furthermore, the flow bay assembly can be readily knocked down which allows the components to be reused in a different location. 
     In an alternative embodiment, illustrated in FIG. 11, each deck module  26 ′ has a laterally outward ledge  50  defined therein. When the modules are interconnected by a key  30 ′, the ledges  50  provide support for the flow rails  22 . In another alternative embodiment illustrated in FIG. 12, a flow bay  20 ″ is made up of a plurality of deck modules  26 ″ which are not individually interconnected by connecting members. Rather, lateral supports  52  maintain the deck members together and the flow rails  22  are supported by channels  50 . Other embodiments will suggest themselves to those of ordinary skill in the art. 
     Changes and modifications in the specifically described embodiments can be carried out without departing from the principles of the invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law.