Abstract:
A cross bar forming a support surface between parallel deck beams of rack-type storage systems to create storage shelves, the cross bars being lockable and readily removable and reusable.

Description:
BACKGROUND OF THE INVENTION 
   The present inventions relate generally to shelf-type storage racks systems and, more particularly, to improved cross bars used to create storage shelves. The cross bars of the present inventions are locked or secured against undesired movement without bolts and the like to create a shelf so that loads are properly supported. The locking cross bars are also readily removeable and reusable. 
   Shelf-type storage racks are widely known in the storage and warehouse industry. Typical shelf-type storage racks include at least four vertical columns rigidly interconnected by generally horizontal deck beams which are positioned in a transverse relation with pairs of columns that are spaced by horizontal and diagonal members commonly referred to as storage rack trusses. The storage rack trusses may be arranged as a series of back-to-back arrays with each array, including the horizontal deck beam, facing an access aisle. As is typical in known, shelf-type systems, a series of wooden slats are placed between the opposing deck beams to form shelves where pallets and other loads may be stored and accessed by warehouse personnel. The front of the shelf is usually adjacent to an access aisle, where warehouse personnel typically use high lifts, fork lifts and the like to place and remove pallets and their loads from the shelves. 
   As indicated, one common way of creating the storage shelves is the use of wooden slats, typically two-by-fours, as cross bars between the deck beams. When using this method, the front and back deck beams are typically roll formed prior to installation to provide a ridge or lip on their upper surface upon which the wooden slats are placed. However, in this configuration, the slats are prone to being knocked-out, skewed or otherwise misaligned between the deck beams as a result of, among other things, contact with a pallet or fork lift or being otherwise inadvertently disturbed by the warehouse personnel. If this shifting or knock-out of one or more slats is unknown to the warehouse personnel, subsequent placement of a load could result in the load falling, leading to injury to the personnel and/or damages to the load, equipment or rack structure. At best, making sure that the slats are properly positioned between the deck beams is time consuming for the warehouse personnel. 
   Another method of creating storage shelves using slats is shown and described in U.S. Pat. No. 5,011,031 (incorporated herein by reference). In this method, wooden cross bars are inserted in the channels between the opposing deck beams. Although an improvement, this method has disadvantages such as increased construction costs and decreased flexibility. 
   Still another known method that may be used to create storage shelves is shown and described in U.S. Pat. No. 6,497,332 B1 (also incorporated herein by reference). This method is particularly useful in storage situations, such as the grocery sector, where only some items stored on a pallet need to be accessed, as opposed to access to the whole load or pallet and its load. Although this system is also an improvement over other known shelf-type storage systems, its configuration is not required in every storage application. 
   SUMMARY OF THE INVENTION 
   The present invention preserves the advantages of the various known rack storage systems and the creation of storage shelves, and also provides new features and advantages. For example, the present invention provides a rack storage system having at least one pair of parallel spaced front columns and at least one pair of parallel spaced rear columns. It also has at least one generally horizontal front deck beam interconnected between at least one pair of spaced front columns, the front deck beam including at least one aperture, as well as at least one generally horizontal rear deck beam interconnected between at least two rear columns. At least one locking cross bar interconnects said front and rear deck beams to form a support surface. The cross bar is adapted at a front end to lockingly engage the aperture on the front deck beam. The locking cross bar is also adapted at a rear end to engage or be supported by the rear deck beam. 
   In addition, the present invention provides an improved locking cross bar for creating, or that can be used to create, a support surface between front and rear deck beams of a rack-type storage system. For example, the present invention provides a rack storage system having at least one locking cross bar having a support surface, a front end and a back end. Means are provided on the front end of the locking cross bar for securing the locking cross bar to the front deck beam to prevent undesired movement of the cross bar, as well as means on the front deck beam to cooperate with said securing means. Securing means may also include a locking tab, hook, lip or other structure to engage the front deck beam cooperating means. Means on the back end of the locking cross bar to prevent undesired movement, lock and/or be supported by the rear deck beam may also be provided. 
   Accordingly, an object of the present invention is to provide rack storage systems using cross bars to securely create shelves between opposing deck beams that support loads or loads stored on pallets. 
   Another object of the present invention is to provide locking cross bars that are secured or locked to at least the front and/or rear deck beam to prevent unwanted movement, knock-out or skewing. 
   Still another object of the present invention is to provide cross bars that may be securely installed without the use of nuts and bolts, welding and the like. 
   Still yet another object of the present invention is to provide cross bars that are easily installed, locked against undesired movement, and yet are easily removable and reusable. 
   Yet another object of the present invention is to provide locking cross bars that may be constructed from a variety of standard structural members having a variety of cross sections. 
   A further object of the present invention is to provide a cross bar that may easily lock to the front and/or rear deck beams using a variety of locking means and methods that prevent undesired movement and permit removal and reuse if desired. 
   Yet a further object of the present invention is to provide locking cross bars that can be retrofitted into existing rack storage systems without major modification to the front and/or rear deck beams or the disassembly of all or substantial portions of the rack system. 
   Still a further object of the present invention is to provide an improved locking cross bar system to create shelves for rack storage structures that saves costs, provides adequate strength, enables system flexibility, and is dependable. 
   Inventor&#39;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. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The stated and unstated features and advantages of the present inventions will become apparent from the following descriptions and drawings wherein like reference numerals represent like elements in the various views, and in which: 
       FIG. 1  is a side perspective view of a typical storage rack system and showing an example of a front deck beam modified in accordance with an embodiment of the present invention; 
       FIG. 2  is a side perspective view of an embodiment of a locking cross bar of the present invention; 
       FIG. 3  is a reverse side perspective view of the locking cross bar embodiment of  FIG. 2 ; 
       FIG. 4  is a cross sectional view of a locking cross bar of the present invention with the cross bar shown in an initial installation position in phantom lines, and in an installed or locked position on the front deck beam in non-phantom lines; 
       FIG. 5  is a side cross sectional view of a locking cross bar of the present invention shown in an installed position on the back deck beam; 
       FIG. 6  is a side cross sectional view of a locking cross bar and front and back deck beams of the present invention showing the locking cross bar in an initial installation position; 
       FIG. 7  is a side cross sectional view of a locking cross bar and front and back deck beams of  FIG. 6  showing the locking cross bar in an intermediate installation position; 
       FIG. 8  is a side cross sectional view of a preferred locking cross bar and front and back deck beams of  FIGS. 6 and 7 , showing the locking cross bar in an installed position; 
       FIG. 9  is a side perspective view of an embodiment of the present invention shown installed between the front and rear deck beams; 
       FIG. 10  is a side perspective view of a preferred embodiment of a locking cross bar shown prior to installation between front and rear deck beams; 
       FIG. 11  is a side perspective view of the preferred embodiment of  FIG. 10  shown in an installed position; 
       FIG. 12  is a side perspective view of a preferred embodiment of a locking cross bar of the present invention; and, 
       FIG. 13  is a front view of the front vertical overhang of the preferred embodiment of the locking cross bar of the present invention. 
   

   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. 
   The structural components and configuration of a typical storage rack truss  12  is shown generally in  FIG. 1 . Such components include a plurality of spaced parallel columns  14 , a plurality of generally horizontal front deck beams  16  ( FIG. 1  also showing a modification, i.e. apertures, holes or slots  13 , to the front deck beams  16  consistent with a preferred embodiment of the present invention) interconnecting front columns  14 , and a plurality of generally horizontal rear deck beams  17  that interconnect the rear columns  14 . Support braces  18  and lateral support members  19  may also be provided consistent with load and design requirements. 
   Usually, there is a front side of the system which is adjacent to an access aisle and a back side of the system to which there is typically no access. However, as will be understood by those of skill in the art, the present inventions may be readily adapted for applications where access to both sides of the storage rack  12  is required. For sake of clarity, however, the present inventions will be described in detail by reference to shelf-type storage systems that are accessed only from one side, that is, the front or access aisle. 
   It will be understood by those of skill in the art that the structural components of storage rack truss system  12  may be selected from a wide variety of materials (e.g., iron, steel or aluminum) having a variety of cross-sectional shapes (such as channels, angles, tubing, I-beams and S-beams). Front and rear deck beams  16  and  17  of the preferred embodiments are described herein as constructed from standard structural members having a channel cross section, which is fairly typical in the industry. 
   Shown generally in  FIGS. 2 and 3  is one embodiment of locking cross bar  20 . Locking cross bar  20  spans between front deck beam  16  and rear deck beam  17 . Locking cross bar  20  provides, among other things, a support surface  21 . When installed, one or more locking cross bars  20  form a shelf or deck upon which pallets (not shown) or loads (not shown) may be placed for storage and access. As will be understood by those of ordinary skill in the art, the strength, spacing and number of locking cross bars  20  will depend upon design considerations such as the loads to be stored and size of the truss system  12 , etc. It will also be understood that sheeting materials may be placed upon the cross bars  20 , if desired. 
   Similarly, locking cross bars  20  are described herein as being fabricated from standard structural members having a right angular cross section, one flange  10  of which is horizontally oriented so that it provides a support surface  21 . However, these particular standard structural components are not required to practice the inventions, as other structural members of different cross sections may also be advantageously fabricated and employed to practice the claimed inventions. 
   In a preferred embodiment, front deck beam  16  (see  FIGS. 4 and 9 ) includes a vertical web with an outer face  30  and a top flange  31  having an inner edge  34 . The distance between face  30  and inner edge  34  of top flange  31  generally defines a flange or support width  32 . Front deck beam  16  also includes a lower flange  33  that is opposed to upper flange  31  and has flange width  32 . Because the preferred front deck beam  16  is constructed from a standard structural channel, top flange  31  and lower flange  33  generally have the same flange width or support structure  32 , subject to manufacturing and/or rolling tolerances. However, equal flange widths, or even the presence of a lower flange  33 , are not necessary to practice the inventions. In the preferred embodiment of the present invention, the outer face  30  of front deck beam  16  is also provided with a series of appropriately spaced and sized apertures or slots  13  (see also  FIG. 1 ) which are used to engage a locking tab  25  of locking cross bar  20  as hereinafter described. Notably, this is typically the only modification to the front deck beam (or other components of the rack system  12 ) required to practice the inventions in their simplest forms. 
   Rear deck beam  17  (see  FIGS. 5 and 9 ) also has a vertical web with an outer face  36  and a top flange  35  having an inner edge  38 . Like the front deck beam  16 , the distance between inner edge  38  and face  36  of top flange  35  defines a flange width or support structure  39 . Rear deck beam  17  also includes a lower flange  37  that is opposed to upper flange  35  and has a flange width  39 . Because in this embodiment rear deck beam  16  is constructed from a standard structural channel member, top flange  35  and lower flange  37  generally have the same flange width  39 , subject to manufacturing and/or rolling tolerances. Again, however, equal flange widths  39 , or even lower flange  37 , are not required to practice the inventions. 
   One embodiment of locking cross bar  20  of the present invention may be seen in more detail by reference to  FIGS. 2 and 3 . Locking cross bar  20  includes a horizontal flange  10  that provides a support surface  21  and a vertical flange  22 . In order to provide clearance for flange widths  32  and  39  of top flanges  31  and  35 , portions of vertical flange  22  are removed from horizontal flange  10  by cutting or other available means. As will be understood by those of skill in the art, a sufficient length of vertical flange  22  must be removed from horizontal flange  10  to enable a front vertical overhang  24  and a back vertical overhang  26  to be formed as hereinafter described. In addition, a sufficient length of horizontal flange  10  must remain after formation of front and back vertical overhangs  24  and  26  to provide for a support leg  23  that is roughly equivalent to or slightly longer than flange widths  32  and  39 , upon which they may rest. In other words, after formation of front vertical overhang  24 , back vertical overhang  26  and support legs  23 , the remaining portion of vertical flange  22  should, within typical manufacturing tolerances, abut (or slightly clear) the inner edge  34  of top flange  31  of front deck beam  16  and the inner edge  38  of top flange  35  of rear deck beam  17 . 
   The remaining portion of vertical flange  22  of locking cross bar  20  includes a front angled portion  28  and a rear angled portion  29  as shown, for example, in  FIGS. 2-5 . Front angled portion  28  and rear angled portion  29  start at an angle from horizontal support leg  23  that meets the inside edges  34  and  38  of the top flanges  31  and  35  of the front and back deck beams  16  and  17 . These angles, although not required, aid in the installation of locking cross bar  20 . 
   In one preferred embodiment, front vertical overhang  24  is formed on one end, i.e., the front end of locking cross bar  20 , by bending down a portion of horizontal flange  10  at a point sufficient to clear front face  30  of front deck beam  16 , while allowing support leg  23  sufficient length to accommodate flange width  32  and rest upon or be supported by upper flange  31 . In one embodiment, front vertical overhang  24  may be bent at an angle slightly greater than 90° to accommodate variations of flange width  32 , manufacturing tolerances of locking cross bar  20  and to help secure locking of cross bar  20  as it spans front deck beam  16  and rear deck beam  17 . In a preferred form of locking means, a locking tab  25  is formed on front vertical overhang  24 . Preferably, locking tab  25  is bent toward the back of cross bar  20  ( FIGS. 3 and 4 ) and is angled slightly upward toward horizontal flange  10  to form a hook shape to help accommodate variations of flange width  32 , manufacturing tolerances of locking cross bar  20  and provide secure locking between the front  16  and rear  17  deck beams. A straight or non-hooked locking tab  25  may also be acceptably employed in lieu of the embodiment having a hooked type tab  25 . 
   Locking cross bar  20  also includes a back vertical overhang  26  which is formed by bending down horizontal flange  10  to form support leg  23  at a point sufficient to clear the rear web  36  of rear deck beam  17  while permitting horizontal leg  23  to be sufficient to clear flange width  39  and rest upon or be supported by upper flange  35  of rear deck beam  17 . Back vertical overhang  26  may be provided with an optional deflected portion  27  that is bent generally toward the rear of locking cross bar  20  as shown in  FIG. 3 . Deflected portion  27  may be provided to accommodate variations of flange width  39 , variations in the spacing of front deck beam  16  and rear deck beam  17 , as well as variations in the fabrication of preferred locking cross bar  20 . 
   Alternatively, it is acceptable to eliminate back vertical overhand  26  (as well as deflected portion  27 ), such that the rear end of cross bar  20  is simply provided with rear support leg  23 , which may rest on or be supported by top flange or support structure  35  of rear deck beam  17 . It may also be desirable to bend the flange creating support surface  21 , slightly downward between the inner edge  34  of front deck beam  16  and the inner edge  38  of rear deck beam  17 , so as to be slightly below top flanges  31  and/or  35 . In this manner, horizontal rotation of cross bar  20  and/or the prying of tab  25  out of aperture  13  is further prevented. This is especially desirable in embodiments of locking cross bar  20  that do not incorporate a back vertical overhand  26 . 
   The installation and operation of one preferred embodiment may be seen by reference to  FIGS. 4-9 . Front support leg  23 , front vertical overhang  24  and locking tab  25  of locking cross bar  20  cooperate with front deck beam  16  and its slots (or other apertures)  13 . As shown in  FIG. 4 , locking tab  25  of front vertical overhang  24  is inserted into slot  13  of front deck beam  16  when locking cross bar  20  is in roughly the position shown in  FIG. 6  and in phantom lines in  FIG. 4 . As locking cross bar  20  is rotated downward (see  FIG. 7 ), the front angled portion  28  clears inner edge  34  of top flange  31 . 
   When in a fully installed position (see  FIG. 8 ), support leg portion  23  rests on the top of top flange  31 . When locking cross bar  20  is in its lowered or installed position, the rear horizontal leg portion  23  rests on top flange  35  of rear deck beam  17 , as shown in  FIGS. 5 ,  8  and  9 . Back vertical overhang  26  and its deflected portion  27  overhang rear deck beam  17  when locking cross bar  20  is in its lowered or installed position, and the width of back vertical overhang  26  (i.e., horizontal flange  10 ) prevents the rear of locking cross bar  20  from moving along a horizontal plane. 
   In this manner, locking cross bar  20  is locked into position between front deck beam  16  and rear deck beam  17  without the use of bolts, welds and the like. Thus, for example, if the front deck beam  16  and/or locking cross bar  20  are inadvertently hit by a fork lift placing or removing a pallet and/or its load  15 , the locking cross bar  20  will remaining in place. 
   In addition, the locking cross bar  20  may be easily removed. When removal is desired, rear vertical overhang  26  is lifted up and rotated toward the front deck beam  16  or front of the system. Once locking cross bar  20  clears the upper flange  31  of front deck beam  16 , locking tab  25  can slide out of slot  13  and locking cross bar  20  may be removed and reused, if desired. 
   As previously discussed, it may be desirable, but is not required, to form vertical overhang  24  at an angle slightly greater than 90%. As a result, when installed as shown in  FIG. 4 , a vertical gap  40  is created and is at its largest when a particular flange width  32  is the smallest. As flange width  32  increases, vertical gap  40  decreases. This helps accommodate, among other things, variations in flange widths, such as flange width  32 . 
   Similarly, it may be desired, but is not required, that locking tab  25  be bent slightly upward, which results in top slot gap  42 . Like vertical gap  40 , slot gap  42  is largest when flange width  32  is at its smallest, as shown in  FIG. 4 . Slot gap  42  decreases as flange width  32  increases. This aids in installation and also helps secure cross bar  20 . 
   The preferred or best representative embodiment of the present invention is shown in  FIGS. 10 ,  11 ,  12  and  13 . In this preferred embodiment, front vertical overhang  24  optionally has a more narrow, or tapered, configuration when viewed from the front as shown in  FIG. 13 . More specifically, front vertical overhang  24  has tapered sides  24   1  and  24   11  that may be cut away as part of the forming process of cross bar  20 . In addition, locking tab  25  is not hook shaped, but instead is flat and roughly horizontal. And, in this embodiment, apertures or slots  13  may be smaller holes or the like. Other than vertical overhang  24  having tapered sides  24   1  and  24   11  and a straight locking tab  25 , the configuration, installation and/or removal of this preferred embodiment of locking cross bar  20  is essentially the same as the other embodiments discussed herein. 
   Also consistent with the present inventions, the rear end, as opposed to the front end, or even both ends of locking cross bar  20  may include locking means or tabs  25  and engage holes or slots  13  on both the front  16  and/or rear  17  aisle beams, as appropriate. 
   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.