Patent Publication Number: US-RE48218-E

Title: System and method for maintaining a minimum separation between pallets positioned on adjacent racks

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-In-Part of and claims the benefit to co-pending U.S. Ser. No. 14/324,840 filed Jul. 7, 2014 which claims the benefit of U.S. Provisional Patent Application No. 61/843,538, filed Jul. 8, 2013, both of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to racks for mounting pallets, and more particularly, to a system and method for maintaining a minimum separation between pallets mounted on adjacent racks. 
     BACKGROUND OF THE INVENTION 
     Pallets are flat transport structures that support goods in a stable fashion as the pallet is lifted by a jacking device such as a forklift, for example. A pallet is the structural foundation of a unit load that enhances handling and storage efficiencies. Goods or shipping containers are often placed on a pallet and secured with strapping, stretch wrap or shrink wrap and then subsequently shipped. While most pallets are made of wood, pallets may also be made from plastic and metal material. 
     In a warehouse environment, pallets are routinely stored on racks which permit the pallets to be stacked on top of one another in a column form. The racks are typically spaced apart from one another by a sufficient distance, so that stacked pallets on one rack can overhang the rack and still maintain a separation from stacked pallets that overhang an adjacent rack. For safety reasons, various insurance and/or legal regulations require a minimum separation between the stacked pallets on adjacent racks. For example, in the event of a fire in the warehouse, these minimum separation regulations may facilitate water coverage from overhead sprinkler systems between the stacked pallets. The minimum separation regulations may depend on the specific insurance and/or legal regulations. 
     Various conventional approaches have been proposed to provide a separation between the stacked pallets on adjacent racks, in order to comply with these insurance and/or legal regulations.  FIG. 1  illustrates one such approach including a Z-stop bracket  110  to attempt to provide a separation  118  between a first pallet  113  positioned on a first rack  112  and a second pallet  115  positioned on a second rack  114 . As illustrated in  FIG. 1 , the Z-stop bracket  110  is attached to the first rack  112  using an attachment means  116 , such as bolts, for example. The first pallet  113  overhangs the first rack  112  and engages the Z-stop bracket  110  in an effort to maintain the separation  118 . An additional Z-stop bracket (not shown) may be attached to the second rack  114  in a similar manner as the Z-stop bracket  110  attached to the first rack  112 , to engage the second pallet  115  and maintain the separation  118 . 
     BRIEF DESCRIPTION OF THE INVENTION 
     A system for maintaining a minimum separation between pallets positioned on racks. The system comprising a double back stop. The stop includes: a first and a second back stop configured to prevent lateral movement of the pallets beyond the back stops, the back stops defining a minimum separation between the pallets; and a middle section connecting the back stops includes a vertical cross-member; and one or more of the following: a clip forming a channel affixed to the double back stop, and/or a web affixed to the double back stop, and/or member affixed to the double back stop, and/or a slot in the double back stop. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the embodiments of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
         FIG. 1  is an end view of an exemplary embodiment of a conventional Z-stop bracket attached to a rack to engage a pallet positioned on the rack; 
         FIG. 2  is a perspective view of an exemplary embodiment of a system for maintaining a minimum separation between a first pallet positioned on a first rack and a second pallet positioned on a second rack according to the present invention; 
         FIG. 3  is a bottom perspective view of the system of  FIG. 2 ; 
         FIG. 4  is a perspective view of the system of  FIG. 2  without the first and second pallets positioned on the first and second racks; 
         FIG. 5  is a perspective view of an exemplary embodiment of the double back stop of the system of  FIG. 2 ; 
         FIG. 6  is a front perspective view of the double back stop of  FIG. 5 ; 
         FIG. 7  is a side perspective view of the double back stop of  FIG. 5 ; 
         FIG. 8  is a front view of the double back stop of  FIG. 5 ; 
         FIG. 9  is a top perspective view of an alternate embodiment of the double back stop of the system of  FIG. 2 ; 
         FIG. 10  is a flowchart illustrating an exemplary embodiment of a method for forming the double back of  FIG. 2 ; and 
         FIG. 11  is a flowchart illustrating an exemplary embodiment of a method for maintaining a minimum separation between a first pallet positioned on a first rack and a second pallet positioned on a second rack. 
         FIGS. 12-14  illustrate an alternate embodiment of the invention with a clip forming a channel for receipt of the rack. 
         FIG. 15  illustrates an alternate embodiment of the invention with a web. 
         FIG. 16  illustrates an alternate embodiment of the invention with a member (i.e., a combination of the clip and the web). 
         FIG. 17  illustrates an alternate embodiment of the invention with a slot. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In describing particular features of different embodiments of the present invention, number references will be utilized in relation to the figures accompanying the specification. Similar or identical number references in different figures may be utilized to indicate similar or identical components among different embodiments of the present invention. 
     The inventor of the present invention recognized that the conventional approaches to attempt to maintain a separation between the pallets on adjacent racks have several drawbacks. For example, the inventor of the present invention recognized that the installation process for securing the Z-stop bracket  110  to the rack  112  of  FIG. 1  is cumbersome, requiring extensive attachment means, such as multiple through bolts. Thus, the inventor proposed the system described herein, which includes a double back stop that involves minimal installation steps, to attach to adjacent racks and maintain a minimum separation between pallets positioned on the adjacent racks. 
     Additionally, the inventor of the present invention recognized that the Z-stop bracket  110  is inherently weak relative to typical lateral loads imposed by the pallets  113 ,  115  and thus frequently bends during use, thereby failing to maintain the separation  118  between the pallets  113 ,  115 . Thus, the inventor proposed the system with the double back stop described herein, which maintains structural integrity in the presence of typical lateral loads imposed by pallets  113 ,  115  and thus maintains a minimum separation between pallets positioned on adjacent racks. 
       FIGS. 2-3  illustrate a system  10  for maintaining a minimum separation  12  between a first pallet  14  positioned on a first rack  16  and a second pallet  18  positioned on a second rack  20 . A double back stop  22  is attached to the first rack  16  and the second rack  20 , to maintain the minimum separation  12  between the first pallet  14  and the second pallet  18 . For purposes of clarity,  FIG. 2  omits the second pallet  18  so that the double back stop  22  is visible between the first and second racks  16 ,  20 .  FIG. 3  illustrates the second pallet  18  positioned on the second rack  20  and the minimum separation  12  maintained between the first and second pallets  14 ,  18  by the double back stop  22 . In an exemplary embodiment, the minimum separation  12  may be selected based on one or more insurance and/or legal regulations. In another exemplary embodiment, the minimum separation  12  may be selected within a range of 5-7 inches, such as 6 inches, for example. However, the embodiments of the system  10  and the double back stop  22  are not limited to any specific range of minimum separation  12  and may be employed to maintain any minimum separation between pallets positioned on adjacent racks. 
     As further illustrated in  FIGS. 2-3 , the double back stop  22  includes a first back stop  24  attached to the first rack  16  to prevent lateral movement of the first pallet  14  beyond the first back stop  24 . The double back stop  22  depicted in  FIGS. 2-3  also includes a second back stop  26  attached to the second rack  20  to prevent lateral movement of the second pallet  18  beyond the second back stop  26 . As illustrated in  FIG. 3 , a minimum distance  25  is maintained between the first backstop  24  and the second backstop  26 , so that the minimum separation  12  is maintained between the first and second pallets  14 ,  18 . In an exemplary embodiment, the minimum distance  25  is approximately equal to the minimum separation  12 . However, the minimum distance  25  may be less than the minimum separation  12 , provided that the minimum separation  12  is maintained between the pallets  14 ,  18 .  FIGS. 2-3  further illustrate that the minimum distance  25  between the first and second backstops  24 ,  26  is maintained by a middle section  28  connecting the first back stop  24  to the second back stop  26  such that the first back stop  24  and the second back stop  26  are spaced apart by the minimum distance  25 . As illustrated in  FIG. 3 , a length of the middle section  28  between the first back stop  24  and the second back stop  26  is the minimum distance  25 . 
       FIG. 4  illustrates the system  10  without the first and second pallets  14 ,  18  positioned on the first and second racks  16 ,  20 . As shown in  FIG. 4 , the first and second racks  16 ,  20  include a grating  58  that extends across a top of the first and second racks  16 ,  20  and over an outer surface  66  of a side  60  of the first and second racks  16 ,  20 . However, the grating  58  does not extend beyond the outer surface  66  of the side  60  of the first and second racks  16 ,  20  at attachment locations  62 ,  64  along the first and second racks  16 ,  20 , where the first and second back stops  24 ,  26  are attached to the side  60  of the first and second rack  16 ,  20 . As further illustrated in  FIG. 4 , the first and second back stop  24 ,  26  attach to the racks  16 ,  20  by extending over an inner surface  68  of the side  60  of the first and second side racks  16 ,  20  to the attachment locations  62 ,  64 . The first and second racks  16 ,  20  and the grating  58  structural arrangement of  FIG. 4  is merely one exemplary embodiment of a pair of racks that can be used with the double back stop  22  of the present invention. Indeed, the embodiments of the double back stop  22  discussed herein may be used to maintain the minimum separation  12  between pallets positioned on any pair of adjacent racks constructed from any structural components. 
       FIG. 5  illustrates the double back stop  22  that is attached to the first and second racks  16 ,  20  of the system  10  discussed above. The double back stop  22  includes the first back stop  24  discussed above which includes a first horizontal member  30  configured to extend across a top of the first rack  16 . The first back stop  24  also includes a first back stop member  38  to extend upward from the first horizontal member  30  by a height  42  to prevent lateral movement of the first pallet  14  beyond the first back stop  24 . In an exemplary embodiment, the height  42  may be selected based on a height of the first pallet  14 . For example, the height  42  may be selected to be less than the height of the first pallet  14 . In an exemplary embodiment, the height  42  may be selected in a range of 3-5 inches, such as 4 inches, for example. The first back stop  24  also includes a first attachment member  44  that extends downward from the first horizontal member  30  by a length along the inner surface  68  of the side  60  of the first rack  16  to attach the first back stop  24  to the first rack  16 . In an exemplary embodiment, the length of the first attachment member  44  may be selected in a range of 1-2 inches, such as 1 inch, for example. 
     As illustrated in  FIG. 5 , the double back stop  22  also includes the second back stop  26  discussed above which includes a second horizontal member  32  configured to extend across a top of the second rack  20 . The second back stop  26  also includes a second back stop member  40  to extend upward from the second horizontal member  32  by a height  42  to prevent lateral movement of the second pallet  18  beyond the second back stop  26 . As with the first back stop member  38 , the height  42  of the second back stop member  40  may be selected based on a height of the second pallet  18 . For example, the height  42  may be selected to be less than the height of the second pallet  18 . In an exemplary embodiment, the height  42  may be selected within a range of 3-5 inches, such as 4 inches, for example. The second back stop  26  also includes a second attachment member  46  that extends downward from the second horizontal member  32  by a length along the inner surface  68  of the side  60  of the second rack  20  to attach the second back stop  26  to the second rack  20 . 
       FIG. 5  further illustrates that the first attachment member  44  includes a hole  43  47 configured to pass a fastener (not shown) through the first attachment member  44  and the first rack  16 , in order to attach the first back stop  24  to the first rack  16 . Similarly, the second attachment member  46  includes a hole  43  47 configured to pass a fastener through the second attachment member  46  and the second rack  20 , in order to attach the second back stop  26  to the second rack  20 . After the first and second attachment members  44 ,  46  are extended along the inner surface  68  of the side  60  of the first and second racks  16 ,  20 , the fastener is passed through the holes  43  and into the inner surface  68 , to secure the first and second back stops  24 ,  26  to the first and second racks  16 ,  20 . In an exemplary embodiment, the holes  43  47 may have a diameter in a range of ⅛-½ inches, such as ¼ inches for example. 
       FIG. 5  further illustrates that the double back stop  22  includes the middle section  28  with a horizontal cross-member  29  that interconnects the first back stop member  38  with the second back stop member  40  along a top of the first back stop member  38  and a top of the second back stop member  40 . As illustrated in  FIG. 5 , the length of the horizontal cross-member  29  is the minimum distance  25 . Additionally, as illustrated in  FIG. 5 , the middle section  28  includes a vertical cross-member  35  that interconnects the first back stop member  38  to the second back stop member  40  along a center  37  of a width of the first and second back stop members  38 ,  40 . Although the embodiment of the vertical cross-member  35  depicted in  FIG. 5  interconnects the first and second back stop members  38 ,  40  along the center  37  of their width, the embodiments of the present invention may position the vertical cross-member  35  to interconnect the first and second back stop members  38 ,  40  at any region along a width of the first and second back stop members  38 ,  40 . In an exemplary embodiment, the vertical cross-member  35  enhances the structural integrity of the double back stop  22  in the presence of lateral loads imposed by the first and second pallets  14 ,  18  against the first and second back stop members  38 ,  40 . In an exemplary embodiment, when the vertical cross-member  35  is integrally connected to the double back stop  22  other than with a welding operation, the vertical cross-member  35  enhances the structural integrity of the double back stop  22 , to withstand up to 3000 pounds of lateral force imposed by the first and second pallets  14 ,  18  on the first and second back stop members  38 ,  40 . In another exemplary embodiment, when the vertical cross-member  35  is integrally connected to the double back stop  22  with a welding operation, the structural integrity of the double back stop  22  is enhanced to withstand up to 4900 pounds of lateral force imposed by the first and second pallets  14 ,  18  on the first and second back stop members  38 ,  40 . These numerical force thresholds are merely exemplary and the embodiments of the present invention are not limited to these thresholds and the double back stop may be designed to withstand greater force threshold of the lateral loads imposed by the first and second racks on the double back stop. 
     As illustrated in  FIG. 5 , a length  52  of the double back stop  22  is a sum of a length  48  of the first horizontal member  30 , a length  50  of the second horizontal member  32  and the minimum distance  25  length of the middle section  28 . As previously discussed, in an exemplary embodiment, the minimum distance  25  is the minimum separation  12 . In one exemplary embodiment, the length  48 ,  50  of each of the first and second horizontal members  30 ,  32  is one half of the difference between the length  52  of the double back stop  22  and the minimum separation  12 . In another exemplary embodiment, the length  48 ,  50  of each of the first and second horizontal members  30 ,  32  is in a range of 4-6 inches, such as 5 inches, for example. As further illustrated in  FIG. 2 , the first and second horizontal members  30 ,  32  each include a rack overhang portion  54  that extends over the side  60  of the rack  16 ,  20  to attach the double back stop  22  to the racks  16 ,  20 . Additionally, as illustrated in  FIG. 2 , the first and second horizontal members  30 ,  32  each include a pallet overhang portion  56  that vertically supports the first and second pallets  14 ,  18  between the first and second racks  16 ,  20 . 
     In one embodiment of the present invention, the first and second back stop members  38 ,  40  and the horizontal cross-member  29  are made from an integral piece of material, such as an integral piece of steel material, for example. The vertical cross-member  35  is integrally connected to the integral piece of material, such as with a welding operation, for example.  FIG. 3  depicts the welding joint  27  between the vertical cross-member  35  and the first and second back stop members  38 ,  40  and the horizontal cross-member  29 . As illustrated in  FIG. 5 , to form the double back stop  22 , the integral piece of material is bent along a first line  31 , to form the first back stop member  38  and is bent along a second line  33 , to form the second back stop member  40 . The integral piece of material is then bent along a third line  39 , to form the first horizontal member  30  and is bent along a fourth line  41 , to form the second horizontal member  32 . The integral piece of material is then bent along a fifth line  43 , to form the first attachment member  44  and is bent along a sixth line  45 , to form the second attachment member  46 . The lines  31 ,  33 ,  39 ,  41 ,  43 ,  45  are spaced apart along the integral piece of material, based on the desired lengths of each of the parts of the double back stop  22 . For example, the first and second lines  31 ,  33  are spaced apart by the minimum separation  12 , so that the minimum distance  25  length of the middle section  28  is the minimum separation  12 . In an exemplary embodiment, the integral piece of material is bent at approximate orthogonal angles along each of the lines  31 ,  33 ,  39 ,  41 ,  43 ,  45 , as depicted in  FIG. 5 . In another exemplary embodiment, the integral piece of material may have a length in a range of 14-17 inches, a width in a range of 2-4 inches and a thickness in a range of 1/16-¼ inches, for example. 
       FIGS. 6-8  illustrate additional views of the double back stop  22  from different angular perspectives, with the structural features previously discussed. 
       FIG. 9  illustrates an alternate embodiment of the double back stop  22 ′ that can be used to maintain the minimum separation  12  between the pallets  14 ,  18  in the system  10  of  FIGS. 2-3 . The double back stop  22 ′ includes the middle section  28 ′ that connects the first back stop  24 ′ to the second back stop  26 ′ with a vertical cross-member  35 ′ with end 37′ and without a horizontal cross-member. As with the middle section  28  of  FIG. 5 , the length of the middle section  28 ′ is the minimum distance  25 . In an exemplary embodiment, the minimum distance  25  is the minimum separation  12  required to be maintained between the pallets  14 ,  18 . Unlike the double back stop  22  of  FIG. 5 , the first back stop  24 ′, the second back stop  26 ′ and the middle section  28 ′ are not formed from bending an integral piece of material at spaced apart locations. Instead, the middle section  28 ′ is integrally connected to each of the first back stop  24 ′ and the second back stop  26 , such as with a welding operation, for example. 
       FIG. 10  illustrates a flowchart depicting a method  100  for forming the double back stop  22  to maintain the minimum separation  12  between the first pallet  14  positioned on the first rack  16  and the second pallet  18  positioned on the second rack  20 . The method  100  starts at  101  by providing  102  an integral piece of material. The method  100  then includes bending  104  the integral piece of material at the first line  31  to form the first back stop member  38  to prevent lateral movement of the first pallet  14  beyond the first back stop member  38 , when the first pallet  14  engages the first back stop member  38 . The method  100  then involves bending  106  the integral piece of material at the second line  33  spaced from the first line  31  by the minimum separation  12  to form the second back stop member  40  to prevent lateral movement of the second pallet  18  beyond the second back stop member  40  when the second pallet  18  engages the second back stop member  40 . Additionally, the bending  106  step is performed, to form the horizontal cross member  29  extending the minimum distance  25  between the first back stop member  38  and the second back stop member  40 . In an exemplary embodiment, the minimum distance  25  is the minimum separation  12 . The method  100  may also include integrally connecting  108  the vertical cross-member  35  to the first back stop member  38 , the second back stop member  40  and the horizontal cross member  29  along a region of a width of the first back stop member  38  and the second back stop member  40 , such as the center  37  of the width, before the method  100  ends at  109 . 
       FIG. 11  illustrates a flowchart depicting a method  200  200′ for maintaining the minimum separation  12  between the first pallet  14  positioned on the first rack  16  and the second pallet  18  positioned on the second rack  20 . The method  200  200′ begins at  201  201′ by providing  202  202′ the double back stop  22  including the first back stop  24 , the second back stop  26  and the middle section  28  connecting the first back stop  24  to the second back stop  26  such that the first back stop  24  and the second back stop  26  are spaced apart by the minimum distance  25  as determined by the middle section  28 . The method  200  200′ further includes attaching  204  204′ the first back stop  24  to the first rack  16  and the second back stop  26  to the second rack  20 . The method  200  200′ further includes positioning  206  206′ the first pallet  14  on the first rack  16  and the second pallet  18  on the second rack  20 . The method  200  200′ further includes inhibiting lateral movement  208  208′ of the first pallet  14  beyond the first back stop  24  and the second pallet  18  beyond the second back stop  26  such that the minimum separation  12  is maintained between the first pallet  14  and the second pallet  18 , before the method  200  200′ ends at  209  209′. 
       FIGS. 12-14  illustrate another alternate embodiment of the invention, double back stop  22 ″. Double back stop  22 ″ includes clips  200 . Clips  200  are affixed (e.g., welded) to the double back stop  22 ″ and are spaced from attachment members  44  and  46  to form a channel  202 . The channel  202  is sufficiently wide for receipt therein of racks  16  and  18 . Double back stop  22 ″ may be affixed (e.g., via bolt or screw  88 ) to racks  16  and/or  18 . Clip  200  may a L-shaped channel member of a flat member. 
       FIG. 15  illustrates another alternate embodiment of the invention, double back stop  22 ″′. Double back stop  22 ″′ includes a web  300 . Web  300  may be integral with vertical cross member  35 , or added to vertical cross member  35 , or added to the double back stop separately from the vertical cross member  35 . Web  300  is affixed (e.g., welded) to double back stop  22 ″′. Web  300  may extend between (or span the space between) attachment members  44  and  46  or may extend only a portion of the distance between attachment members  44  and  46  or may extend between clips  200 . The height (top to bottom) of web  300  may be any height sufficient to add additional lateral strength to the double back stop. The thickness, top to bottom, (or width) of web  300  may be sufficient to add additional lateral strength to the double back stop. 
       FIG. 16  illustrates another alternate embodiment of the invention, double back stop  22 ″″. Double back stop  22 ″″ combines clips  200  and web  300 . Member  400 , combined clip  200  and web  300 , has bent terminal ends  402 . The bent terminal ends  402  define, in part channel  202 . Member  400  may be integral with vertical cross member  35 , or added to vertical cross member  35 , or added to the double back stop separately from the vertical cross member  35 . Member  400  is affixed (e.g., welded) to double back stop  22 ″″. The height (top to bottom) of member  400  may be any height sufficient to add additional lateral strength to the double back stop. The thickness, top to bottom, (or width) of member  400  may be sufficient to add additional lateral strength to the double back stop. 
       FIG. 17  illustrates another alternate embodiment of the invention, double back stop  22 ″″′. Double back stop  22 ″″′ includes slots  500 . Slots  500  are formed in the double back stop so that element (i.e., wires) of grating  58  may fit into slots  500  and the double back stop may sit flush (or flat) on the racks  16  and  18 . Slots  500  extend from any point on horizontal members  30  and  32  (e.g., mid-point on the horizontal members, but not so limited) to the terminal ends of the attachment members  44  and  46 . 
     The double back stop may include any combination of the clip  200  forming the channel  202 , web  300 , member  400  and slot  500 . 
     This written description uses examples to disclose embodiments of the invention, including the best mode, and also to enable any person skilled in the art to make and use the embodiments of the invention. The patentable scope of the embodiments of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.