PALLET SPACER SYSTEM AND METHOD OF USE

Abstract

An elongated integral stop rail device extending the length of a row of pallet racks and carried from the racks by hangers which space the rail device at a desired distance from the lateral extent of the racks. The method involves a determination of the length of the row of racks, assembling a stop rail device to extend that length, and mounting the stop rail device from the respective racks the desired distance lateral of the racks. A pair of integral stop rail devices may be spaced laterally apart to block encroachment of pallets supported on adjacent rows of pallets into a flue space defined between the pair.

Claims

1. A pallet rack system with a vertical flue between a pair of first and second flanking rows of end to end pallet racks spaced laterally apart to form a flue area and comprising: the first and second rows of end-to-end pallet racks extending a predetermined overall distance, and including respective pallet support beams for supporting pallets; respective first and second elongated integral stop rail devices interposed between the respective first and second rows of racks in the flue area and spaced a selected distance apart and the said stop rail devices when in use prevent the said pallet and or load on the pallet from encroaching Into a vertical flue of a predetermined width, the first and second Integral rail devices cooperating to extend the overall distance along the respective first and second rows of racks; and hangers mounted from the racks of the respective first and second rows, including from the vertical planes of the respective first and second proximal sides or the respective first and second racks.

2. (canceled)

3. (canceled)

4. (canceled)

5. The pallet rack system of claim 1 wherein: the first and second integral stop rail devices are constructed of metal.

6. (canceled)

7. The pallet rack system of claim 1 wherein: the respective hangers are formed with the openings spaced laterally apart a distance of at least 6 inches.

8. The pallet rack system of claim 1 wherein: the support beams form and array of a predetermined width or depth for receipt of pallets wider than the predetermined width to project proximally from the proximal sides of the respective first and second racks; and there is a vertical space between said first and second racks where the hangers are constructed with the respective rail openings spaced a selected distance from the said vertical space of the respective first and second proximal sides or the respective first and second racks.

9. (canceled)

10. (canceled)

11. (canceled)

12. (canceled)

13. (canceled)

14. (canceled)

15. (canceled)

16. The pallet rack system of claim 1 wherein: the first and second elongated integral stop rail devices include multiple rail sections.

17. The pallet rack system of claim 1 wherein: the first and second elongation integral fail-stop rail devices are one piece.

18. The pallet rack system of claim 1 wherein: the first and second elongated integral stop rail devices are constructed of metal bar stock.

19. The pallet rack system of claim 1 wherein: the first and second elongated integral stop rail devices are rigid.

20. A pallet rack system with a vertical flue between a pair of first and second flanking rows of end-to-end pallet racks spaced laterally apart to form a flue area and comprising: first and second elongated integral stop rail devices interposed between the respective first and second flanking rows of end-to-end pallet racks, and projecting a length at least equal to the length of a pallet racks and spaced a selected distance apart to be engaged by a pallet's end or the pallet loads loaded on the respective pallet racks to limit egress of the respective pallets and pallet loads from encroaching into a vertical flue of a predetermined width; and hangers mounted from the respective racks and including respective first and second Integral stop rail openings spaced the selected distance apart and receiving the respective first and second integral stop rail devices.

21. The pallet rack system of claim 20 wherein: the Integral stop rail devices include metal bar stock.

22. A pallet rack system of individual for storing pallets and comprising: a plurality of flanking rows of individual, end-to-end pallet racks extending collectively over respective predetermined distances and having respective horizontal pallet load beams disposed in vertically spaced apart horizontal planes for supporting pallets: the plurality of flanking rows of Individual end-to-end pallet racks including pairs of racks formed with respective longitudinal confronting sides; the said rack including vertical posts on the respective confronting sides formed with vertically spaced apart apertures; the load beams including fasteners for removable connection to respective ones of the apertures; a plurality of rigid metal, elongated integral stop rail devices extending the predetermined distance along the respective confronting sides of the racks of the respective rows and disposed above the horizontal planes of the respective load beams, and spaced laterally from the load beams a distance to be engaged by pallets loaded on the respective load beams to limit lateral travel of the pallets when loaded on the respective load beams; a plurality of horizontally elongated hangers extending between the respective flanking rows of racks and connected on their opposite ends to the respective posts; the hangers including pairs of mounting devices spaced a horizontal distance apart for forming there between a flue space of a selected width; the mounting devices mounting the respective rigid metal, elongated integral stop rail devices to be selectively engaged by pallets shifted laterally on their respectively load beams to limit encroachment thereof into the flue space.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 is a top plan view illustrating a row of flanking pallet racks separated by an integral stop rail device of the present invention and illustrating several modifications thereof;

[0019] FIGS. 2, 3, 4, 5 and 6 are detail views, in enlarged scale, taken from the circles 2, 3, 4, 5 and 6 respectively in FIG. 1 and depicting sections of the integral stop rails;

[0020] FIG. 7 is a further embodiment of the integral stop rail device system of the present invention;

[0021] FIG. 7A is an end view of a pair of flanking rows of pallet racks defining a flue space incorporating integral rail stop devices to form flue spaces;

[0022] FIGS. 8, 9, 10 and 11 are detail sectional views in enlarged scale, taken from the circles designated 8, 9, 10 and 11, respectively, in FIG. 7A;

[0023] FIG. 12 is an end view of a pair of flanking rows of pallet racks separated by integral stop rails of the present invention;

[0024] FIGS. 13, 14 and 15 are detail views, in enlarged scale, taken from the respective circles 13, 14 and 15 in FIG. 12;

[0025] FIG. 16 is a partial end view of a pair of rows of pallet racks incorporating a modification of the integral stop rail of the present invention;

[0026] FIGS. 17, 18 and 19 are detail sectional views of end fittings that may be incorporated in the integral stop rail device of the present invention;

[0027] FIGS. 20, 21, 22 and 23 are partial perspective views of rail systems incorporating the present invention; and

[0028] FIG. 24 is a flow diagram of a method of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] Referring to FIG. 1, the present invention includes one or more elongated, integral, stop rail devices, generally designated 31, extending along the juxtaposed sides of rows of pallet racks 33 and spaced above the extended planes 34 of load beams 35, disposed in horizontal planes 37 and spaced laterally from the proximate edges of the racks. The stop rail devices are, in some instances, carried from the racks by mounting elements which may be in the form of modified metal hangers or straps known as row spacers, generally designated 41. In some embodiments, the straps may be constructed to cooperate in maintaining both the lateral spans between the racks and the minimum spacing between the juxtaposed edges 38 and 40 of the pallets and their respective loads 42 (FIG. 7A) to maintain a minimum lateral space of at least 4 to 6 inches or so between the juxtaposed edges of pallets to leave an unencumbered flue space top-to-bottom and end-to-end as required by the fire authorities of many localities. As will be described below, many municipalities in earthquake-prone areas require stabilizing of adjacent racks, as by spacer strap devices such as that shown in FIG. 7 to stabilize adjacent rows with each other and positively maintain spacing between those rows. In some embodiments I adopt the expedient of modifying those straps to act as mounts for the integral rail stops of my invention.

[0030] As will be appreciated by those skilled in the art, modern day warehouses have grown to the point where most exceed 10,000 square feet and only about 37% are less than 25,000 square feet, and an equal number exceed 100,000 square feet. Each warehouse is of its own configuration, typically incorporating exterior walls and interior posts or columns, the configuration of which must be taken into account in designing the layout for the installation and organization of pallet racks, access to opposite sides of flanking rows of racks. It would be of great benefit to the industry if a system were available to allow for racks arranged in a row to be modified by adding rail stops extending the full length of the rows of the different lengths dictated by the particular warehouse layout.

[0031] Experience has shown that a fire danger exists in warehouses or other facilities used for storing merchandise on pallets stacked on racks. Referring to FIG. 7A, a minimum horizontal spacing should be maintained between the proximate edges 38 of pallets 44 an their loads 42 supported on back-to-back racks throughout the full height and lengths of the rows of racks to provide vertical openings between racked pallets to act as unobstructed flues 46 throughout. Both vertical and horizontal spacing is important to maintain a clear vertical flue between to vent heat throughout the height and length from any fires that may start in lower parts of the racks. This open vertical and horizontal flue allows for ceiling or in-rack sprinklers, to spray directly down on the flames to limit horizontal spread of the fire. It is also important that water reach the lower tiers to act directly on the base of the fire. In fact, many municipalities and governmental agencies have enacted codes to establish the minimum spacing between pallets mounted on such racks so as to maintain a minimum open-distance of six inches or so between the respective pallets carried on the racks. The situation is complicated by the fact that the lateral lengths of the pallets are often greater than the lateral widths of the respective support beam structure so there is overhang of, say three inches, on one or both sides of the beam structure. It is this problem to which one aspect of the present invention is directed.

[0032] As will be appreciated by those skilled in the art, in these embodiments, the hanger straps act as anchors and may result in the stop rail devices being disposed a short distance into the flue space, as for instance 2-3 inches depending on the cross section of the stop rail. While meeting some municipal codes this encroachment is prohibited by most final plan checkers who require the stop rail devices to be spaced laterally outside the unobstructed flow area.

[0033] To that end, for one aspect of the present invention I provide a fully unobstructed flue 46 dictated by the space between elongated integral stop rail devices 31 (FIG. 7) to project longitudinally along the side of rows of individual racks. The stop rail device may be carried from hanger straps mounted to a rack or between adjacent racks. As will be appreciated by those skilled in the art, the load beams 35 defining the horizontal beam structure are typically supported at multiple levels to provide vertically spaced support decks for each of the respective racks. I take advantage of this construction to construct and arrange my integral stop rail system so that, in some embodiments, the stop rail devices and their mounts can serve as spacers and may cooperate with the stop rail devices to maintain a selected minimum horizontal distance between pallets supported on flanking racks.

[0034] As noted, the width or depth of a standard pallet may be 48 inches and the depth of a rack defined by the support beams only 42 inches, thus leaving a pallet overhang on each side. By positioning my integral stop rail device, for instance, three inches from the extended vertical plane of the rear edge of the rack defined by the stop rail, when the forklift operator places the loaded pallet on the support beams, the stop rail device will limit the rear overhang to three inches, thus tending to maintain the pallet centered and the desired spacing between the pallets on flanking rows of racks. As will be appreciated by those skilled in the art, this predetermined distance of overhang may vary but in many current commercial embodiments, will be set at 3 inches.

[0035] For the purpose of illustration, I have shown five embodiments of the integral stop rail device in FIG. 1 and depicted in detail in FIGS. 2-6. The device may be in the form of square or round tubes 185 (FIG. 2) or 187 (FIG. 3), wires or cables 31 (FIG. 4), angle stock 195 (FIG. 5) or flat stock 191 (FIG. 6). The stop rail device may be made up of segments of tubes, stock or wire which may be available in various different lengths such as 20 or 40 feet long, and may be connected together on their proximate ends by coupling devices generally designated 61 (FIGS. 4-6) to form an integral full length rail. As will be appreciated, the 40 foot lengths will be sufficiently long so the one piece will itself extend the length of several 8 or 12 long racks arranged in a long row.

[0036] The segments may be coupled together by the couplings 61 which may be in the form of, for instance, a wire splice, clamp, internal or external members or, in some embodiments, telescoping members to be friction fit together, or just received in the opposite ends of threaded collars. For exemplary purpose, coupling members 61 are shown in FIGS. 3-4. Internal couplings may include square or round tube segments (FIGS. 2 and 3) to be friction fit in place or secured by fasteners such as tek screws 205 or 211 (FIGS. 2 and 3). This then establishes an integral rail which may extend for several hundred feet to reach the full length of a warehouse.

[0037] For the purpose of this description, the term integral stop rail device or stop rail is intended to mean an elongated strip extending the length of two or more racks and made up of one or more segments to act as a continuous stop. The term rail is intended to mean a strip of metal or like material such as, for example, and without limitation, tubing, bar stock, rod, wire, cable or cord of rigid material or drawn tight to act as stops and limit lateral movement of pallets positioned on adjacent pallet decks. Connection of segments may be by welding or coupling or the like or, in some instances, the proximate ends of the various lengths of rail segments may be merely abutted together in proximate relationship with one another and in general longitudinal alignment with one another. The term hanger strap is intended to mean any type of rigid hanger to be connected to one or more racks and having a rail mounting element for mounting the rail spaced a selected distance from the respective pallet decks.

[0038] Referring to FIG. 7, the hanger devices 186 may take many different forms depending on the particular configuration of the integral stop rail devices, such as, for example, straps 182, 187, 189, and 185 including, respectively, an array of bores for receiving wires, 237, (FIGS. 7 and 16) an array of vertical slots for receiving strips 84 (FIGS. 7,7A and 9) a pair of square openings for receipt of square tubes 185 (FIGS. 7,7A and 11) or right angle slots for receipt of angle irons 190 (FIGS. 7, 7A and 10).

[0039] As show in FIGS. 7A-11, these integral stop rail devices may be positioned vertically above the levels of the respective support beams to be engaged by the proximate sides 38 and 40 of the respective pallets or their respective loads maintain a minimum flue width at 46.

[0040] While in many applications I select spacer straps to mount at their opposite ends from flanking racks as described below, I have also found that mounting straps 91-91 can be mounted cantileverly to serve as hangers. Referring to FIGS. 20-23, the straps 91-91 are formed at their bases with a pair of vertically spaced horizontal slots 48 aligned with pairs of apertures 50 in vertical posts by 52, for instance shoulder bolts (not shown). The hanger straps 91-91 are formed with respective vertical slots 77, angle slots 76 and bores 78, all spaced a selected distance from the slots 48 so as to space the openings a set distance laterally from the load beams in the pallet deck (FIG. 5). In some embodiments the strap 91-91 may be configured to cooperate in establishing a spacing between adjacent rows of racks for the purpose of maintaining the so-called flues 46 of the required width between the respective racks in the respective flanking rows.

[0041] In practice, I have found that 14 gauge tubes, 1 or 1 inches square or 1 inch in diameter can be coupled together to serve the purpose of acting as an integral stop rail device. Other cross sections will occur to those skilled in the art, such as, for instance, T-bar or angle iron 187 (FIGS. 10 and 14), round or square tube 189 and 185 (FIGS. 2, 3 and 11), channel strips or flat bar 84 (FIG. 21) and cable, cord or heavy gauge wire 237 (FIGS. 4, 8 and 16).

[0042] As noted above, in some locales, particularly those prone to earthquakes, the local codes require that racks in adjacent rows be coupled together as by metal strips or straps tending to stabilize the racks and pallets in the event of a seismic event. For various configurations some codes even establish the necessary horizontal spacing between flanking racks, such as at least 10, 12 or 18 inches. I have found it expedient to construct straps 165, 157 and 151 (FIGS. 12-15) to facilitate these coupling and spacing requirements. In some embodiments I form the straps 151, 165 and 157 with the openings spaced horizontally apart to receive square tubes, angle irons or round tubes spaced apart to maintain a space of approximately 4 inches, or in some instances 7 inches, or even other selected distances so the spacing of the elongated stop rail devices mounted therein will stop the pallets at the required position necessary to meet local code.

[0043] As will be appreciated by those of skill, a great advantage of one embodiment of the present invention is that the hanger straps or rails may be manufactured in an assembly line as a kit to be available when the time comes to connect rows of conventional pallet racks in situ to establish the desired stop for the pallets and/or set the desired spacing between side-by-side racks.

[0044] Referring to FIG. 24 in practice the method of the present invention the workman will determine the overall lengths of the combined racks of a row and then select the necessary rail segments at 175 to be coupled together and make the hanger straps at 174 (in most instances manufactured on an assembly line basis ahead of time) with the selected spacing between the mounting elements and stop rail mounting elements. The hanger straps may be retrieved from inventory and mounted from the respective racks at 181 for then mounting the integral stop rail device 31 at 183. It will be appreciated that in some instances, the sections of the stop rail devices are inserted longitudinally through the rail mounting elements and sometimes just slid downwardly into place from the open top of the rail-receiving openings.

[0045] As will be appreciated, in practice, during fabrication the hanger strips may be stamped out with the specific lateral lengths to correspond with the desired spacing of mounting bores or slots in the rack posts and the spacing of the rail mounting elements from those mounting bores. When installation is to be completed the hanger straps may be mounted to the respective racks at the desired level above the level of the respective pallet support beams and spaced the selected distance laterally of the edges of such tacks to accommodate overhang of the pallets.

[0046] The particular sections of the elongated integral stop rail segments may then be positioned in the aligned windows, slats or bores in one convenient installation step. The proximate ends may then be coupled together as by couplings 61 or for the wire or cable embodiments with wire clamps or convenient spacers. In some instances, the proximate ends of segments of tubes will be telescoped together for friction fit or joined by spot welding, threading and/or other couplings known in the art, or as described below.

[0047] The racks will then be available for receipt of the pallets delivered by forklift so that the pallets may be loaded from the bay side of the respective racks and the lateral travel thereof will be limited by engagement with the elongated integral stop rail devices 31 at the far side of the rows of racks. For example, in some embodiments, the spacing between the respective racks will be maintained at the desired spacing of 6, 7, 10, 12, 18 inches or other spacing as prescribed by code and incorporated in the manufacture of the hanger straps.

[0048] Referring to FIGS. 12-15, for exemplary purposes, I have shown a pair of flanking rows of racks 181 and 183, connected together by the respective spacer straps 151, 157 and 165 to cooperate in maintaining the stability between the respective rows of racks, and also serving as a mount for spacing the respective integral stop rail devices a desired distance apart for limiting pallet travel on the respective load beams at the various levels of the racks.

[0049] For the purposes of illustration, I show the flanking rows of pallet racks configured with various modifications of stop rail devices 185, 187 and 189, square and round tube and angle carried from respective openings spaced the desired distance apart in the straps. In some embodiments I form my hangers with two pairs of openings for each the stop rail devices to thus provide the option for installation to provide, for instance a 6 wide or 12 wide flue.

[0050] The embodiment shown in FIG. 16 includes a rectangular hanger 184 for connecting between rows of racks and formed with a pattern of four bores 233 arranged in a rectangular pattern to, when mounted by bolts through the mounting slots 240 to the vertical posts 183 via square apertures 238, space the pairs of vertically spaced bores approximately three inches horizontally from the lateral extent of the racks. The pairs of vertically aligned bores are spaced about six inches apart horizontally to establish a six inch flue. Extending through the respective bores 233 are wire cables 237. The cables 237 may include tensioners on their respective ends, such as nuts 241 screwed over the threaded ends to press turn buckles or the like. In some embodiments, I substitute heavy gauge wire for the cables.

[0051] In some embodiments, the hangers at the ends of the racks include extra reinforcement around the respective bores, such as over-sized washers 238 or the like, so that the cables may be anchored through such washers to facilitate the hangers 231 carrying the stress of tensioning and shock of the cables being bumped along their lengths by pallets being loaded on and offloaded from the pallet decks.

[0052] Thus, installation of the particular integral rails formed by such wires may be achieved by mounting the hangers from the adjacent racks and threading the wires through the respective bores 233. Tension may be applied to such wires as by a tensioner and the ends crimped off, clamped or screwed tight by the nuts 241 to hold thereon.

[0053] Referring to FIGS. 17-19, in some embodiments, I conveniently anchor the ends of the stop rail devices, as by a nut and bolt stop 192, cross bolt 196 or anchor bolt 198 on a flange of the angle stop rail.

[0054] From the above it will be apparent that the present invention provides an economical and effective apparatus for manufacturing original equipment or adding stop apparatus to existing racks to maintain the desired positioning of pallets on the racks and in some instances to also maintain the desired spacing between the adjacent rows of racks. My integral stop rail device may be constructed of relatively inexpensive components, such as sections of angle bar, bar stock, square tubes or even wire stretched taut and supported at the opposite ends from anchors. My system has particular utility for retro-fitting onto existing racks installed in warehouses having a pre-established configuration dictated by structural columns and the like constraining the engineer to specified spacing of the racks to accommodate such columns and still allow for access by fork trucks loading and unloading the pallets.

[0055] Although the present invention has been described in detail with regard to the preferred embodiments and drawings thereof, it should be apparent to those of ordinary skill in the art that various adaptations and modifications of the present invention may be accomplished without departing from the spirit and the scope of the invention. Accordingly, it is to be understood that the detailed description and the accompanying drawings as set forth hereinabove are not intended to limit the breadth of the present invention.