Patent ID: 12258211

The figures are for illustration only and should not be interpreted as limiting. Similar parts are assigned the same reference numerals. The proportions of the parts are illustrative and the invention can be practiced outside the scale of the drawings, which are not necessarily to scale.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present disclosure may be understood more readily by reference to the following detailed description of the disclosure, taken in connection with the accompanying figures, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed disclosure.

Also, as used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.

A multi-level, multi-column rack storage system with no aisles between many of the columns of storage rows of is shown generally inFIGS.1and2as a storage rack100. Storage rack100includes an array of vertical support columns110, which support horizontal beams115, to provide structural support. Storage rack100includes a matrix of storage bays101, extending from a storage bay front101fwhere a pallet130of goods131is loaded and unloaded, to a storage bay rear101r. In some embodiments of the invention, bay101has two “fronts101f” so that pallets130of goods131can be loaded and unloaded from both ends of bay101.

As indicated, rack100supports a plurality of pallets130that are loaded with an assortment of goods131in a matrix of storage bays101. An automated pallet transportation cart300, shown inFIGS.2and3, is provided to transport pallets130of goods131to a location in bay101between bay front101fand bay rear101r. Pallet cart300can be loaded and unloaded into and out of storage bay101from one or both ends of bay101, depending on particular circumstances and construction specifications and space allotments.

Each bay101includes a pair of parallel support rails120. Support rails120extend in a rearward direction from storage bay front101fto storage bay rear101r. Support rails120include a pallet support surface125, on which a plurality of pallets130, with a variety of goods131can be supported thereon, with rails120underneath.

Each pair of rails120also includes a cart support surface126at a level below pallet support surface125. Each cart300includes four wheels320for riding on cart support surface126of rails120of storage bay101. Cart300also includes a raiseable lifting platform340(sometimes called a deck or deck lid) for raising pallets130off pallet support surface125and carrying pallets130to the desired location in bay101, then lowering them onto support surface125of rails120. Pallets130can weigh well under or up to 1000 lb., 2000 lb., even up to 3000 lbs. or more when loaded with goods131. Typically, the combined weight of pallets in a storage bay lane will exceed 4000 lbs. and can exceed many times that weight. However, under certain circumstances, the weight will be far less. Carts300can weigh over 400 lb, even over 650 lb.

A top view of a single rail120of a storage bay101is shown inFIG.4; a side view of rail120is shown inFIG.5; and an end view is shown inFIG.6. A pair of rails120is shown inFIG.7. As indicated above, pallets130of goods131rest on pallet support surface125and wheels320of carts300ride on cart support surface126.

Carts300can be costly. It is therefore common to shuffle a single cart among several lanes101. Carts300are typically moved about rack100with a fork lift. Often, a storage bay is more than 8 feet high off the floor/ground. They can even be over 20 feet off the floor. It can be difficult to properly position cart300on rails120, with wheels320properly located on cart support surface126.

Referring now toFIGS.9and10, a cart security structure900is provided for catching pallet transportation carts300that inadvertently fall between rails120. Rails120are typically positioned should be about 25-35 inches apart, typically about 30-32 inches apart. As shown inFIGS.8and9, rails120can be secured to vertical columns110with a suitable support member111.

In a preferred embodiment of the invention, security structure900is formed of a plurality of horizontal cross beams910. Preferably, there should be at least 3 cross beams910, more preferably at least 4 cross beams910, even more preferably four to six beams910. In one particularly preferred embodiment of the invention, security structure900is formed with five cross beams910. As noted above, it is important that security structure900be formed with mostly open space, so that chunks of wood and other items that inadvertently come off the pallets will not collect thereon. Therefore, cross beams910should be no more than about 2-5 inches wide in plan view from the front to rear direction, preferably about 2-3 inches wide. The space between beams910should be more than about 5 inches wide, preferably more than about 7 inches wide. In some embodiments of the invention, it is possible to include cross structures that are perpendicular to or at an angle to beams910, so long as a place where items can collect is not created.

Security structure900should not have any large open spaces over at least the first inches into bay101that are larger than a dimension of cart300, so that cart300cannot fall therethrough. Some carts can have a height as short as 8 inches. Therefore, in one embodiment of the invention, if beams910are horizontal, they should be less than 7 inches apart, to prevent a cart300from falling therethrough. In preferred embodiments of the invention, the open spaces should not have a dimension over 10 inches, preferably not over 7 inches wide. Security structure900should be at least two, preferably at least 5 inches below the rails120.

In operation, a cart300can be loaded into a top (or other) bay101, such that wheels320of cart300rest on respective cart support surfaces126of rails120. If an error occurs, and cart300falls between rails120, it will be caught by security structure900and calamities can be prevented. Therefore, security structure should be able to support at least 500 pounds, preferably over 1000 pounds.

By way of example, rails120can be made from steel of at least 16 gauge, preferably 16 to 7 gauge, or thicker. Steel at least 1/16 thick, preferably 1/16 to 3/16 inch thick is preferred. Beams910of structure900should be made from steel of at least 12 gauge, preferably about 12-8 gauge, or thicker. Steel at least 0.1 inch thick, preferably 0.1 to 0.16 inch thick is preferred.

A safety structure700in accordance with a preferred embodiment of the invention is shown generally inFIGS.11and12. As discussed above, storage rack systems in accordance with the invention employ a plurality of vertical columns710that rise from a warehouse floor (not shown). A plurality of lengthwise support members720and diagonal support members721extend from the front to the rear of the storage rack and can be used to connect and help stabilize vertical columns710. A plurality of horizontal support members extend sideways from support columns710, including a front face cross beam731, a first internal cross beam732, and so on. Cross beams731and732can be L-shaped angle bracket in shape, having a horizontal wall with a horizontal plane and a vertical wall, with a vertical plane.

Security structure700includes a pair of lengthwise support members740and an assembly of cross beams750thereon. Support member740is in the form of an L-shaped angle bracket, having a horizontal surface741and a vertical wall742. Cross beams750are convex, so as not to provide a flat surface, where chunks of wood that might be chipped off of pallets can accumulate. Thus, cross beams750are formed as an angle bracket with an L-shaped cross section. The vertex of cross beams750points up, and the ends of the two arms rest on horizontal surface741of support member740. In preferred embodiments of the invention, cross beams750are welded to support members740. A front end of security structure740is attached to front face beam731and a rear end of security structure700is attached to first internal beams732with a plurality of attachment clips760.

Attachment clips760have the form of an L-shaped angle bracket. A front facing surface of a front facing arm761of front attachment clip760is bolted to the vertical wall of front face beam731. A rear facing surface of a rear facing arm765of rear attachment clip760is bolted to the vertical wall of first internal beam732. A side facing surface of a side facing arm762of front attachment clip760is bolted to the vertical wall742of support member740. A side facing surface of a side facing arm766of rear attachment clip765is bolted to vertical wall742of support member740. Thus, security structure700is bolted to horizontal beams731and732with clips760.

Note that where this application has listed the steps of a method or procedure in a specific order, it may be possible, or even expedient in certain circumstances, to change the order in which some steps are performed, and it is intended that the particular steps of the method or procedure claim set forth herebelow not be construed as being order-specific unless such order specificity is expressly stated in the claims.

While the preferred embodiments of the devices and methods have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the inventions. Modification or combinations of the above-described assemblies, other embodiments, configurations, and methods for carrying out the invention, and variations of aspects of the invention that are obvious to those of skill in the art are intended to be within the scope of the claims.