Patent Publication Number: US-2012031866-A1

Title: Decking Member

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. application Ser. No. 12/496,269, filed on Jul. 1, 2009 entitled DECKING MEMBER. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     Embodiments of the present invention generally relate to decking. Some embodiments may be used in shelving systems. The disclosed systems also relate to decking for stairs and other types of structures and structural systems. 
     2. Description of the Related Art 
     Heavy-duty shelving systems are often made of steel frames with separate decking for the shelves. The decking is often made of slats of wood or a wielded wire grid. These racks can be used for hand-stacking applications and for pallet supports. These types of heavy-duty shelving systems are frequently used in factories, warehouse type stores, home improvement type stores, storage facilities, distribution centers, etc. 
     As these systems are frequently used in a public and/or permanent setting, they can be subject to certain regulations under state and local building codes. These regulations can include fire safety mandates that require certain fire ratings, as well as the requirement that a certain percentage of water pass through the shelving units (i.e., from overhead sprinkler systems) to reach the ground. 
     The currently available systems are often overly heavy, thereby reducing the capacity of the shelving unit. This is because of the weight of the decking takes away from the maximum load the system can handle. Thus, the heavier the decking, the less storage capacity in terms of weight the system can hold. In addition, heavy decking systems are difficult for individuals to install and/or manipulate. More than one person is often required to adjust shelves that can weigh half their body weight and more. Other problems experienced by the current systems include increased costs associated with wielding each joint of the wire grid, the large gaps that can form between wooden slats creating a safety issue, as well as the inability to meet certain state and local building codes. 
     SUMMARY OF THE INVENTION 
     For the reasons discussed above, there exists a need for improved decking and shelving systems that, for example, meet and/or exceed current building codes, reduce the cost of manufacture, and reduce the weight of the shelving system while increasing load capacity. 
     A decking member configured for use with a shelving unit according to certain embodiments can comprise a plurality of panels, each panel comprising a plurality of slots; first and second side supports being on opposite sides of each of the plurality of panels, each connected to and extending along the length of one side of separate panels among the plurality of panels, the side supports extending in a direction generally transverse to the panels; and at least one side support from each of the plurality of panels connected to another side support from an adjacent panel. Each of the plurality of panels and its first and second side supports can be roll-formed of a single piece of material. 
     In certain embodiments, the at least one side support from each of the plurality of panels connected to another side support from an adjacent panel is joined together, preferably with a weld or a mechanical connector such as a rivet. In some embodiments, the connection between the side supports is open such that water can pass into the connection from the upper surface of the panels. Of some of these embodiments, the connections and the slots make up an open deck of at least 50%. 
     Some embodiments of a decking member have slots formed by punching a hole and then drawing the hole to form the slot. At least a portion of the material circumscribing the hole used to form the slot is bent to extend generally in the direction of the side supports. This can increase the strength of the decking member. 
     A shelving system according to certain embodiments can comprise a frame and at least one decking member. 
     A method of making a decking member can comprise first cutting a first piece of material to a desired shape, wherein the first piece of material is flat. Then, punching out a plurality of slits along a length of the first piece of material, wherein the length is substantially in the center of the first piece of material. Next, roll-forming the first piece of material to create side supports substantially in an L-shape such that the first piece of material is no longer flat. Then, drawing the plurality of slits to create a plurality of slots larger than the slits, wherein at least a portion of the excess material circumscribing the slits is forced downward from a top of the first piece of material. Additional steps can include cutting, punching, roll-forming and drawing a second piece of material in substantially the same manner as the first piece of material and connecting a side support of the first piece of material to a side support of the second piece of material. 
     In certain methods the step of connecting a side support of the first piece of material to a side support of the second piece of material comprises welding the side supports together. Welding is preferably provided, or mechanical means such rivets, although other connecting methods would be effective. 
     Some methods can further comprise cutting, punching, roll-forming and drawing a third and fourth piece of material in substantially the same manner as the first piece of material and connecting one side support of the third piece of material to a side support of the second piece of material and the other side support of the third piece of material to a side support of the fourth piece of material. 
     A decking member of some embodiments can comprise a plurality of panels, first and second side supports, and at least one center support. One or more of the panels can comprise a plurality of slots. The slots can allow the decking to have a minimum of 50% open deck. The first and second side supports may be positioned on opposite ends of the decking member, each connected to and extending substantially along the length of one side of separate panels among the plurality of panels. In addition, the side supports can be generally perpendicular to the panels and can form the shape of an L or C and may include a V-notch along the top. At least one center support may be provided between the panels and may serve to connect adjacent panels together as well as provide load support to the decking system. According to some embodiments, the decking member can be roll-formed of a single piece of material and the relationship of the plurality of panels, first and second side supports, and at least one center support can be established by a series of folds in the single piece of material. Alternatively, the center support may comprise two discrete portions secured together to form the center support. In this embodiment, a first center support portion extends from a first panels, and a second center support portion extends from a second panel. The two portions may then be secured together when the first and second panels are placed adjacent to each other to become part of the multi-panel decking system. Whether integral or not, the at least one center support can comprise a region generally perpendicular to the panels and a base. The base may comprise a triangular configuration, or one of a number of other geometries that serve to assist in sustaining a load borne by the decking member. Where the latter component is used in a two portion embodiment, half of the triangular base is associated with one panel and the other half with the adjacent panel, with both halves secured together. The panels may be welded together, preferably with rivet clinch welding, whether the two panels abut at the center support. 
     A shelving system according to some embodiments can comprise a frame and at least one decking member. The decking member can comprise a plurality of panels, first and second side supports, and at least one center support. Each panel can comprise a plurality of slots. The first and second side supports can be on opposite ends of the decking member, each can be connected to and extending along the length of one side of separate panels among the plurality of panels. In addition, the side supports can be generally perpendicular to the panels and can be formed in the shape of an L or C and may include an indentation along the top. The at least one center support can be between and connecting the panels. The at least one center support can have a region perpendicular to the panels and can have a triangular base. According to some embodiments, the decking member can be roll-formed of a single piece of material. 
     A decking member of certain embodiments can further comprise a plurality of hooks. The plurality of hooks can be part of the single piece of material or can be welded or otherwise joined to the member. The plurality of hooks according to some embodiments can be attached to the center support at a bottom of the triangular base. 
     These and other objects of embodiments of the present invention will become readily apparent upon further review of the attached drawings and specification. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features and advantages of embodiments of the invention, and the manner of attaining them, will become apparent by reference to the following description of preferred embodiments of the invention taken in conjunction with the accompanying drawings. 
         FIG. 1  is an isometric view of an embodiment of a shelving system incorporating some embodiments of decking members. 
         FIG. 2  is an isometric view of an embodiment of a decking member. 
         FIG. 3  is a top view of the decking member of  FIG. 2 . 
         FIG. 4  is an end view of the decking member of  FIG. 2 . 
         FIG. 5  is a detail view of a side support of an embodiment of a decking member. 
         FIG. 6  is a detail view of a center support of an embodiment of a decking member. 
         FIG. 7  is a detail view of a hook and center support on an end of an embodiment of a decking member. 
         FIGS. 8A-C  illustrate certain detail views of slits and slots on a decking member. 
         FIG. 9  is an isometric view of another embodiment of a decking member. 
         FIG. 9A  is an isometric view of another embodiment of a decking member. 
         FIG. 9B  is an end detail view of the decking member of  FIG. 9A . 
         FIG. 10  is a top view of another embodiment of a decking member. 
         FIG. 11  is a top view of the decking member of  FIG. 10  shown during a manufacturing process according to certain methods. 
         FIG. 12  shows an end view and an end detail view of the decking member of  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The embodiments shown in  FIG. 1  illustrate a rack or shelving unit  10  with decking  2  and frame  3 . The rack  10  is shown with two decking members  2 . In other embodiments, the rack  10  can have 1, 2, 3 or more decking members  2 . Additionally, certain embodiments can comprise multiple racks  10  with multiple decking members  2 . Other embodiments can comprise one rack  10  with multiple frames  3  and multiple decking members  2 . 
     The decking  2  according to one embodiment can be of one piece steel construction that is roll-formed. Roll-forming can include a continuous bending operation in which a long strip of metal (typically coiled steel) is passed through consecutive sets of rolls, or stands, each performing only an incremental part of the bend, until the desired cross-section profile is obtained. In the preferred embodiment, the steel used can be 20 gauge steel. 
       FIGS. 2-4  show four panels  4  connected by three center supports  6  and with two side supports  8 . The front and back ends both show two integral hooks  12  for attachment to the shelving system. The hooks shown can form part of the one piece construction. The panels can have a plurality of slots  14  thereon. The slots can allow for water to pass through the decking and can contribute to the ability of the decking to meet and/or exceed certain state and local building codes requirements. The slots are described in greater detail below. 
     The individual supports will now be described.  FIG. 5  illustrates one embodiment of a side support  8 . The side support  8  of the illustrated embodiment is generally “L” or “C” shaped with a substantially horizontal edge  18  and a substantially vertical edge  20 . In some embodiments, side support  8  can have an indentation  16  that runs along the length of the side support  8 . In some embodiments, the indentation  16  runs along or near the top region of the side support  8 . The indentation  16  can have a variety of different shapes. The indentation  16  can add to the structural integrity and strength of the side support  8  and can facilitate the manufacturing process by providing a guide to direct the member through various production machines. The side support  8  of  FIG. 5  is shown with a “V” shaped notch  16  that runs along the top length of the side support  8 . Alternatively, side support  8  need not include an indentation  16 . Horizontal edge  18  can also have a bent end  22 . Bent end  22  can add to the structural integrity of the side support  8  and additionally it can ensure that no sharp edges are exposed where someone is likely to contact them. Substantially horizontal edge  18  can be configured to engage ledges (not shown) in the system frame to assist in supporting the decking member  2  in the system. 
     In the embodiments where an optional indentation  16  is employed, an in particular a V-notch indentation as shown in  FIG. 5 , the side support  8  consists of five folds or bends. There is a first fold  24  where the V-notch  16  and the panel  4  connect. A second fold  26  can be found at the point of the V-notch  16 . A third fold  28  is at the connection between the vertical edge  20  and the V-notch  16 . There is a fourth fold  30  at the connection between the vertical  20  and horizontal  18  edges. And finally, a fifth fold  32  along the bent end  22 . The side support  8  of other embodiments can have more or less folds or bends. For example, the indentation  16  of other embodiments could be U-shaped increasing the number of folds by one. As another example, the side support  8  of certain embodiments can add another fold to bent end  22  to better protect against exposed sharp edges. It is preferred, however, that side support  8  doesn&#39;t include indentation  16  and, therefore, can be formed with fewer folds. 
     Turning now to  FIG. 6 , a center support  6 , which can be an I-beam type member, is shown. As illustrated, the left and right sides of the center support  6  are preferably mirror images of each other; therefore the following description only describes the left side. The center support  6  shows the top of the I-beam formed by panels  4 . Substantially vertical segment  34  forms the substantially vertical part of the I-beam. The bottom of the I-beam may be in the form of a triangle with sides  36  and bottom  38 . In other embodiments the right and left sides are not mirror images. In some embodiments the center support  6  can have a different form than that described above. For example, the base can have a different shape than triangular, such as circular, or flat, or rectangular. 
     In this particular embodiment, the center support  6  shown has 6 folds or bends, with 3 per side. Once again, the following will only describe the left side. A first fold  40  is at the top of the I-beam. A second fold  42  is at the bottom of the substantially vertical segment  34  of the I-beam and at the top of triangle side  36 . Finally there is a third fold  44  where the side  36  and the bottom  38  of the triangle meet. As with the side support  8 , the center support  6  can have more or less folds or bends and still be within the scope of this disclosure. Importantly, the center support  6  may comprise discrete parts secured together rather than a integral single-sheet arrangement. For example, in one set of embodiments, bottom piece  38  is split at some point along the horizontal, whether at the half-way point or off-center, so that adjacent panels comprise discrete panels rather than connected panels. In these embodiments, piece  38  comprises two pieces secured together, preferably by rivet clinch welded although other securing techniques are contemplated, to form the bottom of the I-beam-type center support  6 . With this arrangement, it is also preferred that both vertical segments  34  are securd together, preferably by rivet clinch welded although other securing techniques are contemplated. Thus, alternative presentations of the center support  6  are provided, some reflecting adjacent panels being integral with each other, and some reflecting adjacent panels being discrete members secured together at the center support. 
       FIG. 7  shows another embodiment of a center support with a hook  12  attached thereto. The hook shown has three parts, a top  48  and two sides  46 ,  50 . Side  46  is shown attached to the center support at fold  52 . The hook also has a fold  54  and  56  where the top  48  connects with the sides  46  and  50  respectively. In some embodiments, there are no hooks. In some embodiments the hook or hooks are attached to the decking member  2  at locations other than the center support  6 . The embodiments shown in  FIGS. 1-4  illustrate the use of four hooks, in some other embodiments more or less hooks can be used. In some embodiments, the one or more hooks  12  can cooperate with the one or more side supports  8  and/or the one or more center supports  6  to engage a frame to form a finished system. In some embodiments, the one or more hooks  12  may be connected at more than one location. For example, the hooks  12  may be welded or otherwise attached to both the center support  6  and the panel  4 . In some embodiments, no hooks  12  are used. 
     Returning now to  FIG. 2 , a plurality of slots  14  are shown along the top of the panels  4 . The slots  14  of one embodiment can be formed by metal punching. In one preferred embodiment the slots  14  are ½″ drawn holes. The slots  14  of the preferred embodiment can form at least a 50% open deck, while maintaining the safety and strength of the decking. This can help to satisfy state and local building codes, as they often require a minimum 50% open watershed area to satisfy fire requirements. The slots  14  of other embodiments can from a 50% open deck. Still other embodiments can from less than a 50% open deck. The slots  14  can increase the strength of the deck. The number, size, position and spacing of the slots  14  can be varied according to different embodiments. 
     In some embodiments, slots  14  can be press cut from the panel  4  with the excess material removed and discarded or otherwise utilized. As shown in  FIGS. 8A-C , in some embodiments, the slots  14  may be formed by first cutting an appropriately sized slit or slits  58  in the panel  4  and second moving the sides of the slit  58  downward to form the slot  14 . In some embodiments, the sides of the slit  58  can be moved downward and outward to form the slot  14 . Moving or pressing the sides of the slit  58  downward or downward and outward away from the top surface of the decking member  2  leaves a substantially smooth interface on the top surface of the panel  4  where the slots  14  meet the panel  4 . The side edges of the subsequently formed slots  14  may be ground, sanded, or otherwise manipulated to reduce the likelihood they would cut a hand or other appendage that may come into contact therewith. Bending the material out of the way, thereby leaving some or all of the pre-existing panel material around the slots  14 , can increase the structural integrity of the decking member  2  while providing necessary watershed properties for the decking member  2 . 
     By bending the sides of the slit  58  downward, or downward and outward, a substantially planar surface can be formed on the top of the panel  4 . This can allow for the decking member  2  to have increased strength and yet still function well as part of a shelving unit, for example, where boxes or containers, etc. can easily be placed and moved around on the decking member  2 . 
     In some embodiments, traction on the top surface of the decking member  2  can be increased by moving or bending the sides of the slits upward or upward and outward such that the edges of the slots project above the top surface of the panel  4 . In some embodiments, it may be advantageous to form the slots  14  by removing some material and bending the remaining material to control how far the exposed edges project from the surface of the decking member  2 , whether upward or downward. 
     The slots  14  formed on the decking member  2  can increase the strength of the decking member  2 . For example, manufacturing the slot  14  as a drawn-hole from a slit  58 , as explained above, can increase the strength of the decking member  2  verses a decking member  2  without slots  14  or with slots  14  that are solely punched out of the material. 
     The slits  58  of the various embodiments can be of different shapes. For example, rectangular, rectangular with two opposing rounded ends, elliptical, circular, etc. In some embodiments, as shown in  FIG. 8 , the slits  58  are dumbbell shaped with circular ends and a narrower connecting region. The slots  14  can also be various shapes in the different embodiments. The shape of the slot  14  may be similar to the shape of the slit  58 . The shape of the slot  14  may be very different from the shape of the slit  58 , as in  FIG. 8 . In some embodiments, the ends of the formed slots  14  are approximately ½ inch from the edges of the panels  4 . 
     In some embodiments, the slits  58  can be formed in the shape of a dumbbell with 7/16 inch holes at the ends and 5/32 inch channels running between them. In some embodiments the slits  58  can be 4 23/32 inch from center to center of the holes. The slots  14  that are formed can be 17/32 inch channels running along the length of the slot  14 . In some embodiments the length is 5¼ inches where the panel is 6⅛ inches. In some embodiments there can be 13/16 inch from center to center of adjacent slots  14 . 
     Turning now to  FIGS. 9 ,  9 A and  9 B, another embodiment of a decking member  2 ′ is shown. The decking member  2 ′ can also be used in a rack or shelving unit together with a frame. The decking member  2 ′ can be manufactured according to the desired size. In some embodiments, the decking member  2 ′ can comprise one or more decking units  60 . Where there are more than one decking units  60 , the decking units can be joined together along the side supports  8 ′ to create the decking member  2 ′. For example the decking units  60  can comprise a connection  62 , wherein the connection can be formed by welding, spot welding, riveting, bolting them together, etc. The decking member  2 ′ can comprise one, two or more decking units  60  and preferably comprises four decking units  60 . The decking member  2 ′ can also comprise hooks (not shown) or other devices to connect the decking member  2 ′ to a frame or shelving unit. In some embodiments, the decking member  2 ′ can fit into or on a frame such that hooks or other connection devices are not necessary. 
     The decking member  2 ′ can have an at least a 50% open deck. In some embodiments the slots  14 ′ form at least a 50% open deck. In some embodiments, the sides of the decking units  60  that are connected together along the side supports  8 ′ can be open to water flow. In these embodiments, these joints together with the slots  14 ′ can form at least a 50% open deck. 
       FIGS. 10 and 11  illustrate a decking member  2 ′ according to certain embodiments and part of a method of making a decking member  2 ′. The decking member  2 ′ in  FIG. 10  can be the final product or it can be one of the decking units  60  to be made into a final decking member  2 ′ having multiple connected decking units  60 .  FIG. 11  shows the decking member  2 ′ in an intermediary condition. The decking member  2 ′ or decking unit  60  can be formed of a single piece of material, such as metal. According to certain methods, a piece of material can be cut to a desired size and the slits  58  can be punched out, with for example, a punch press. The piece of material can then be roll formed to attain the desired final shape as discussed previously. Either before or after this step, slots  14  can be formed as also discussed above. 
     Referring to  FIG. 12 , a front view of a decking member  2 ′ or decking unit  60  is shown. The decking member  2 ′ or decking unit  60  can have a side support  8 ′. The side support  8 ′ shown, has a substantially vertical edge  20 ′ and a substantially horizontal edge  18 ′. Also shown is a bent end  22 ′. Similar to the prior embodiments the decking member  2 ′ or decking unit  60  can have a side support  8 ′ different from that shown, with for example, an indentation or other shape. 
     Embodiments of the disclosed invention have many benefits. The decking can be manufactured in varying widths and depths accommodating all bay sizes. In some embodiments, the decking member has an outer width dimension extending between the side supports on the ends in the range of approximately 20 to approximately 48 inches. In some embodiments, the outer width dimension is in the range of approximately 24 to 27 inches. In some embodiments, outer width is one of 24, 36, 42 or 48 inches. In some embodiments, the panels can be one of approximately 4, 5, 6 and 7 inches. In some embodiments, the decking has an outer length dimension in the range of approximately 15 to approximately 50 inches. In some embodiments, the outer length is one of approximately 20.5, 32.5, 38.5 and 44.5 inches. In some embodiments, the ratio of the width to the length of the decking member is approximately 1 to 1. In some embodiments, the ratio is approximately 1 to 2. In some embodiments, the height of the decking member can be one of approximately 1, 1.5, 1 9/16 and 2 inches. The decking can have a durable powder coat finish process, which is generally preferred over other types of finish. 
     The front to back triangular shaped channels can create a flat surface and add strength. Also the embodiments with multiple decking units connected to form the decking member can also have a flat surface and add strength. The different embodiments can be manufactured to create a lightweight deck allowing one-person installation. 
     In addition, the disclosed embodiments can have a high weight capacity and, in particular, a high weight capacity versus their own weight. For example, applicants have found that a 20 gauge, 24½″×44½″ deck design according to some embodiments has a 3500 lb. capacity, with a 2 to 1 safety factor that can meet certain Rack Manufacturers Institute (RMI) guidelines. 
     While the described in terms of specific embodiments, it is implicit that the invention is not limited to these disclosed examples. The invention may be embodied in many different varieties and should not be construed as limited to the embodiments set forth herein; rather these embodiments are provided by illustration purposes only. Undeniably, many modifications and other embodiments of the invention will come to mind of those skilled in the art to which the invention pertains, and which are intended to be and are covered by this disclosure, the drawings, and the claims.