Patent Publication Number: US-2018027963-A1

Title: Returnable industrial rack system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit under 35 U.S.C. §119(e) of U.S. Patent Application No. 62/367,194, filed Jul. 27, 2016, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     This specification relates generally to the field of mechanical engineering and, more specifically, to non-welded, reusable, and returnable industrial racks. 
     BACKGROUND 
     Standard industrial shipping racks are custom-made and welded together, representing single-purpose rack units for shipping and storage of specific items of predetermined size and weight, such as automobile parts for a specific model and year. One the need for the custom, single-purpose racks has passed, they are cut apart for scrap. These racks typically are made of 11-gauge steel tubing. This is typically due to the thicker tubing better handling the rigors of the welding process, as well as being suited for use in harsh environments and with forces experienced in shipping and industrial applications, as well as the need to ship more cumbersome items than may be accomplished with traditional mail services. However, such specific-use, conventional racks are heavy, costly, labor intensive, inefficient, and wasteful. Moreover, damage incurred to these racks must be hand repaired, necessitating removal of the rack from use, return to its manufacturer, and, typically, hand-cutting and welding the damaged portions to rebuild the rack. There is a need for more efficient systems for shipping and storing goods. 
     The present novel technology addresses these needs. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a perspective view of the present novel technology. 
         FIG. 2  depicts a top view of the present novel technology. 
         FIG. 3  depicts a side view of the present novel technology. 
         FIG. 4A  depicts a second perspective view of the present novel technology in a first example configuration. 
         FIG. 4B  depicts a perspective view of the present novel technology in a second example configuration. 
         FIG. 4C  depicts a perspective view of the present novel technology in a third example configuration. 
         FIG. 4D  depicts a perspective view of the present novel technology in a fourth example configuration. 
         FIG. 5A  depicts an example process flow associated with the present novel technology. 
         FIG. 5B  depicts a continuation of the example process flow of  FIG. 5A  associated with the present novel technology. 
     
    
    
     Like reference numbers and designations in the various drawings indicate like elements. 
     DETAILED DESCRIPTION 
     Before the present methods, implementations, and systems are disclosed and described, it is to be understood that this invention is not limited to specific synthetic methods, specific components, implementation, or to particular compositions, and as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting. 
     As used in the specification and the claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed in ways including from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another implementation may include from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, for example by use of the antecedent “about,” it will be understood that the particular value forms another implementation. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. 
     “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. Similarly, “typical” or “typically” means that the subsequently described event or circumstance often, though may not always, occur and that the description includes instances where said event or circumstance occurs and instances where it does not. 
     The details of one or more embodiments of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims. 
       FIGS. 1-5B  depict various perspectives and embodiments associated with the instant novel industrial/shipping rack system  100 , which typically may include structural member(s)  105 ; junction point(s)  108 ; bracket(s)  110 ; fastener(s)  115 ; container(s)  120 ; container wall(s)  125 ; and/or parcel(s)  130 . Specifically,  FIGS. 1-3  depict perspective, top, and side views, respectively, of the present novel rack system  100 . 
     Typically, industrial rack system  100  may be assembled by connecting two or more structural members  105  together at one or more junction points  108  with removable and reusable fasteners  115 , typically bolts. At junction and/or traversal points  108  (i.e., where one or more structural members  105  may change direction), one or more brackets  110  may be used to join the two or more structural members  105 . Further, one or more fasteners  115  typically may be used to connect the one or more structural members  105  and/or the one or more bracket members  110 . 
     Structural members  105  typically may be tubing, and are typically formed from a rigid and/or semi-rigid structural material, such as metal, plastic, ceramics, cermets, composites, combinations thereof, or other convenient structural materials, and/or the like. More typically, structural members  105  may be 14-gauge steel square tubing. In other implementations, members  105  typically may be thin-walled tubing, such as aluminum, steel, alloys, combinations thereof, and/or the like, more typically with square cross-sections. 
     Further, some implementations may have members  105  being drilled, tapped, slotted, and/or otherwise configured to accept one or more brackets  110  and/or fasteners  115 . For example, four structural members  105  may be assembled together to define a rectangle by fastening the ends of each of the four members  105  to one end of another adjacent, perpendicularly oriented member  105  by threading fastener  115  through bracket  110  at its corner and then through member  105 , thus forming a strong industrial/shipping rack  100 , or portion thereof, while maintaining a relatively low weight compared to conventional industrial rack systems. 
     In still further implementations, members  105  may have a plurality of points at which member  105  may accept one or more fasteners  115  and/or brackets  110 . For example, one example member  105  may have drilled and tapped apertures  108  spaced at regular intervals, such as every one, two, four, and/or the like inches, along member  105 , allowing for a multitude of potential fastening locations. While many implementations may be standardized to a singular fastener type and/or size, other implementations may allow for a multitude of fastening types. For example, some implementations may allow for threading, slotting, interference fitting, locking, and/or any other fastening mechanism to join members  105 , brackets  110 , and/or fasteners  115 . 
     Bracket  110  similarly typically may be a rigid or semi-rigid joining member, such as a straight bracket or angle bracket, typically tapped, drilled, slotted, and/or otherwise configured to connect to structural members  105  and/or fasteners  115 . For example, bracket  110  may be a rigid ninety-degree steel bracket that is drilled and tapped to receive one or more fasteners  115  before fasteners  115  then pass into one or more structural members  105 . 
     In some other implementations, brackets  110  may allow preferential slippage at one or more locations of bracket  110 . For example, one fastening point may be drilled and tapped to rigidly and fixedly receive and hold members  105  together, while another point may allow for members  105  to slide along a slot, rotate through an aperture, and/or the like. This may, for example, allow some members  105  and/or brackets  110  to move during (dis)assembly and/or (un)loading stages. Such modular movement is unheard of in conventional, welded industrial/shipping rack systems. 
     Fasteners  115  typically may be any fastening structure and/or mechanism known in the art to sufficiently secure targets. For example, fasteners  115  may be bolts, screws, nails, magnets, hook-and-loop fasteners, adhesives, hooks and eyes, objects and receiving slots, and/or the like. Typically, fasteners  115  may be bolts and/or locking mechanisms (e.g., nuts, washers, compounds, and/or the like). 
       FIGS. 4A-4D  depict a further, nonexclusive example configurations of present rack system  100 .  FIGS. 4A-4D  may typically depict typical configurations of system  100  configured using modular industrial rack system  100 , typically depicting use cases where container  120  typically may be bounded by container wall  125  and containing one or more parcels  130  that may be supported by system  100 . For example,  FIG. 4A  typically may be designed and constructed such that one or more central aisles may allow dynamic loading and/or unloading of container  120 . In such an example, as depicted in  FIG. 4A , rack  100 , members  105 , brackets  110 , and/or fasteners  115  may be configured such that parcels  130  move toward the aisle(s). Conversely,  FIG. 4B  depicts container  120  having may be configured having racks  100  and no aisle. Such racks  100  may be tailored to specific sizes for parcels  130  and/or dynamically configured, broken down, and/or reconfigured for each use case. 
       FIG. 4C  depicts a perspective view of the present novel technology in a third example configuration where system  100  may further include lifting zone  135  that may also include lifting aperture  140  and/or lifting portion  145 . In some implementations, operators loading racks  100  into containers  120  may use machinery (e.g., lifts, loaders, jacks, and/or the like) to load fully laden racks into the containers  120 . For example, a forklift may be driven with the fork into apertures  140  and then lift in lifting portion  145 , effectively creating a modular, lightweight pallet on a modular, reconfigurable industrial rack, which does not exist for conventional welded rack systems. 
       FIG. 4D  depicts a perspective view of the present novel technology in a fourth example configuration having a nonstandard container  120 . For example, while many shipping containers  120  may be rectangular in shape, system  100  may be infinitely reconfigurable to suit a particular environment. For example, as depicted in  FIG. 4D , system  100  may be tailored to fit a hexagonal container  120  using horizontal and angled members  105  in conjunction with straight and/or angled brackets  110 . Such custom configuration using conventional industrial/shipping rack fabricating techniques would necessitate destroying such welded, custom structures. Conversely, system  100  may simply be disassembled, stored, and then redeployed and reconfigured for the next rack  100  requirement without creating unnecessary waste product or requiring destructive, one-way demolition. 
       FIGS. 5A-5B  depict an example process flow associated with the present novel technology, which typically may include the steps of: receiving predetermined rack design  150 ; connecting structural members, brackets, and fasteners to form racks  155 ; continue connecting step until rack design constructed  160 ; confirming constructed rack conforms to predetermined rack design  163 ; locating complete rack design in container  165 ; placing parcels on complete racks  170 ; shipping laden container  175 ; removing parcels from racks  180 ; disassembling racks into structural members, brackets, and fasteners  185 ; and/or storing structural members, brackets, and/or fasteners for reuse  190 . This example process flow is, however, nonexclusive and for illustrative purposes of one typical use instance for system  100 , and steps may be repeated, omitted, subcycled, and/or modified as desired. 
     During receiving rack design  150 , one or more industrial/shipping rack  100  designers may receive one or more rack designs that may be built using system  100 . Designs may be based on templates, custom, mixed, and/or the like. In some implementations, designs may be created on a platform snapping/converting dimensions to system  100  components (e.g., member  105  sizes, angles, etc.), and in other implementations, input designs may be scaled and/or otherwise altered to fit system  100  specifications and/or inventory on hand. 
     After receiving and fitting the design (i.e., prototyping and design), connecting structural members, brackets, and fasteners to form racks  155  typically may be accomplished by assembling system  100  components as described above according to the design. This process may then typically continue for each modular rack subsection and/or module under step  165 : locating complete rack design in container. Thus, one or more complete racking designs may be created using typically standardized system  100  components. 
     In some implementations, placing parcels on complete racks  170  may be performed, loading parcels  130  onto the completed racking in container  120 , while in other implementations, parcels  130  may be loaded onto racks prior to locating racks in container  120 . For example, parcels  130  may be loaded onto racks and then loaded racks may be placed in container  120  using a lift (as depicted in  FIG. 4C ). 
     Shipping laden container  175  may then complete the typical transit stages of process, and removing parcels from racks  180  may next commence. As above, depending on design and/or locating of racks in container  120 , parcels  130  may be removed from racks  100  before and/or after removing racks  100  from container  120 . 
     Further, disassembling racks into structural members, brackets, and fasteners  185  and/or storing structural members, brackets, and/or fasteners for reuse  190  typically may be performed at this point. During these operations, racks  100  typically may be nondestructively disassembled into their component parts (e.g., members  105 , brackets  110 , and/or fasteners  115 ) and inventoried/stored until a new industrial rack design is submitted and built. Thus, the present novel rack system  100  may be used to design, construct, ship, deconstruct, and store for future designs without permanent and/or destructive conventional industrial/shipping rack building processes. 
     In some implementations, racks  100  may be produced in an assembly line fashion, typically with reduced design and build times, and a shorter lead time from concept to prototype. These racks  100  may also result in reduced labor cost and need for highly skilled assembly labor. Further, damaged modular rack units may be more easily repaired, requiring only standardized and/or off-the-shelf replacement parts, rather than a ground-up and piecemeal restoration. Additionally, the present, novel industrial rack units  100  typically may also be lighter than their welded, conventional counterparts, reducing shipping weight and cost without sacrificing strength. 
     In operation, the present novel rack system may be enjoyed by operationally connecting two or more structural members with one or more fasteners to define one or more rack units, positioning the one or more rack units in a shipping container, loading the one or more rack units with cargo to define one or more laden rack units, transporting shipping container with the one or more laden rack units to a destination, unloading the one or more laden racks to yield one or more unladen racks, disassembling the one or more unladen racks to separate and yield the two or more structural members and the one or more fasteners, and/or storing the two or more structural members and the one or more fastener for reuse. 
     In some further operations, the rack system may be further enjoyed by also receiving one or more rack designs, where the one or more rack units are based on the one or more rack designs, and continuing the connection of the respective two or more structural members and the one or more respective fasteners until the one or more rack designs are fully realized. 
     In still further operation, the present novel system may be enjoyed by receiving one or more racks with one or more damaged portions, where the one or more damaged portions are selected from one or more structural members, one or more fasteners, and combinations thereof; removing the one or more damaged portions; and replacing the one or more damaged portions with one or more repair portions, wherein the one or more repair portions are selected one or more structural members, one or more fasteners, and/or combinations thereof. 
     In yet further implementations, operation of the present novel rack system may include constructing using one or more brackets and/or where the one or more structural members are thin-walled, metal tubing (typically, but not limited to, 11-gauge steel). 
     In additional operations, the present novel rack system may be constructed and deconstructed by operationally connecting one or more structural members, one or more brackets, and one or more fasteners to form one or more industrial rack units, wherein the one or more structural members are constructed from thin-walled metal tubing; continuing the connecting step until the rack unit complete; positioning the one or more industrial rack units in one or more shipping containers; and nondestructively disassembling the one or more rack units back into the one or more structural members, the one or more brackets, and the one or more fasteners, wherein the one or more structural members, the one or more brackets, and the one or more fasteners may continue to be reconstructed into one or more rack units. In some instances, operation may further include storing the one or more structural members and the one or more fasteners for reuse, measuring cargo to be shipped to determine cargo dimensions, where the rack unit has a cargo volume that snugly accommodates the cargo dimensions, receiving one or more rack schematics, loading the at least one industrial rack unit, shipping the one or more shipping containers to one or more predetermined destinations, unloading the one or more industrial rack units, placing one or more parcels on the one or more rack units, removing the one or more parcels from the one or more rack units, and/or converting the one or more rack schematic specifications based on one or more inventory of the one or more structural members, the one or more brackets, and the one or more fasteners. 
     Still further implementations of operation may include repairing one or more damaged rack units by replacing one or more damaged portions on site by disconnecting the one or more damaged portions from the rest of the rack unit, removing the one or more damaged portions to define one or more gaps, inserting one or more undamaged portions into the one or more gaps, and operationally connecting the undamaged portion to the rest of the rack unit. 
     While the novel technology has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. It is understood that the embodiments have been shown and described in the foregoing specification in satisfaction of the best mode and enablement requirements. It is understood that one of ordinary skill in the art could readily make a nigh-infinite number of insubstantial changes and modifications to the above-described embodiments and that it would be impractical to attempt to describe all such embodiment variations in the present specification. Accordingly, it is understood that all changes and modifications that come within the spirit of the novel technology are desired to be protected.