Enhanced storage support platform

Abstract

Warehouse support structures capable of supporting heavy loads are supported by support members coupled to horizontal support beams, attached to vertical columns. The structure can comprise wire a mesh platform. The front end can be bent down, to nest against a horizontal support beam. The rear end can be bent up, over the horizontal to act as a pallet safety stop. It can also extend rearwards from the horizontal beam to provide additional support surface area. The construction presents a smooth, easy to assemble, snag free construction.

Claims

1. A storage system, comprising: a support member extending in a rear direction from a front end of the support member to a rear end of the support member, the support member having an upward facing load bearing surface and the front and rear ends each having a connection portions securable to a support beam, respectively; a deck structure on the load bearing surface of the support member, the deck structure comprising an assembly of substantially parallel spaced rods extending in the rear direction joined to a plurality of substantially parallel spaced horizontal members, perpendicular to the substantially parallel spaced rods, the deck structure having a central deck portion and defining a horizontal load bearing plane; the deck structure having a front deck portion extending in a front direction opposite the rear direction, from a front end of the central deck portion, the front deck portion extending in the front and down directions at a decline from the load bearing plane to a front edge portion, the front edge portion extending downward from the front deck portion, the front edge portion having a plurality of the substantially parallel spaced horizontal members attached thereto on a front direction facing side; and the assembly having a rear deck portion extending from the central deck portion upwardly in the rear direction at an upward incline from the load bearing plane to a rear edge portion, the rear edge portion extending from the rear deck portion in a substantially upward direction, and the rear edge portion having a plurality of the substantially parallel spaced horizontal members attached thereto.

2. The storage system of claim 1, and comprising a front and a rear horizontal support beam, the front horizontal support beam having a top flange above a bottom flange and a web therebetween, defining a concave inner surface facing the rear horizontal support beam, wherein the front edge portion is nested between the concave inner surface of the front horizontal support beam and the connection portion of the front end of the support member.

3. The storage system of claim 2, wherein a bolt having a bolt head extends, in sequence, from the bolt head, through the front horizontal support beam, then through the front edge portion and then through a corresponding connection portion, in that order.

4. The storage system of claim 1, wherein the support member is cold formed from a single piece of metal having a central section with a U-shaped, curved, dome-like cross section with an upwardly pointing apex.

5. The storage system of claim 1, wherein the support member has an L-shaped cross section, with a flat horizontal upper wall and a vertical wall extending downward from a vertex with the upper wall.

6. The storage system of claim 5, wherein each connection portion comprises an L-shaped metal piece.

7. The storage system of claim 1, wherein a rear endpoint of the rear edge portion extends at least about 2 inches above the load bearing plane.

8. The storage system of claim 1, wherein a rear endpoint of the rear deck portion extends about 2-6 inches above the load bearing plane.

9. The storage system of claim 2, wherein a rear endpoint of the rear deck portion extends at least 2 inches in the rear direction from the rear beam.

10. The storage system of claim 2, wherein a rear endpoint of the rear deck portion extends about 2-12 inches in the rear direction from the rear beam.

11. The storage system of claim 1, wherein the front deck portion extends downwards from the central deck portion at a first angle to the first edge portion and then further downwards at a second angle, and the front edge portion is substantially perpendicular to the load bearing plane.

12. The storage system of claim 1, wherein the rear deck portion extends upwards from the central deck portion at a first upward angle to the rear edge portion and then extends further upwards to a rear endpoint at a second upward angle.

13. The storage system of claim 12, wherein the first upward angle is about 5°-40°, and the second upward angle is about 35° to 85°.

14. The storage system of claim 1, wherein, the load bearing plane is configured to support loads of up to 3000 lbs.

15. A storage deck system, comprising: a front and a rear horizontal support beam defining a front direction from the rear horizontal support beam to the front horizontal support beam and a rear direction from the front horizontal support beam to the rear horizontal support beam, the front horizontal support beam having a top flange above a bottom flange and a web therebetween, defining a concave inner surface facing the rear horizontal support beam; a support member extending in a rear direction from a front end of the support member to a rear end of the support member, the support member having an upward facing load bearing surface, and the front and rear ends each having a connection portions, respectively secured to the respective front and rear support beams; a deck structure on the load bearing surface of the support member, the deck structure comprising an assembly of substantially parallel spaced rods extending in the rear direction joined to a plurality of substantially parallel spaced horizontal members, perpendicular to the substantially parallel spaced rods, the deck structure having a central deck portion and defining a horizontal load bearing plane; the deck structure having a front deck portion extending in a front direction opposite the rear direction, from a front end of the central deck portion, the front deck portion extending in the front and down directions at a decline from the load bearing plane to a front edge portion, the front edge portion extending downward from the front deck portion, the front edge portion having a plurality of the substantially parallel spaced horizontal members attached thereto on a front direction facing side; and the assembly having a rear deck portion extending from the central deck portion upwardly in the rear direction at an upward incline from the load bearing plane to a rear edge portion, the rear edge portion extending from the rear deck portion in a substantially upward direction, and the rear edge portion having a plurality of the substantially parallel spaced horizontal members attached thereto.

16. The storage deck system of claim 15, wherein an end-point of the rear edge portion extends at least about 2 inches above the load bearing plane.

17. The storage deck system of claim 16, wherein the rear end portion extends upward at a first upward angle from the central deck portion at an angle of about 5°-40°, and the rear edge portion deflects further upward at a second angle of about 35° to 85° to the load bearing plane.

18. The storage deck system of claim 15, wherein the rods comprise steel wire with a diameter of at least 8 gauge.

19. The storage deck system of claim 15, wherein the central deck portion is over 30 inches in the length direction.

20. The storage deck system of claim 17, wherein first upward angle is about 5°-30° to the load bearing plane and the second upward angle is about 45°-85° to the load bearing plane.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 illustrates a first embodiment of a formed support member of the storage rack in accordance with aspects of the present disclosure;

(2) FIG. 2 illustrates a second embodiment of a formed support member of the storage rack in accordance with aspects of the present disclosure, wherein FIG. 2A is a top view, FIG. 2B is a front view and FIG. 2C is a side view;

(3) FIG. 3 illustrates a third embodiment of a formed support member of the storage rack in accordance with aspects of the present disclosure, wherein FIG. 3A is a top view, FIG. 3B is a side view and FIG. 3C is an end view;

(4) FIG. 4A illustrates a top view of a deck of a storage rack in accordance with aspects of the present disclosure; FIGS. 4B and 4C illustrate side views of the deck of the storage rack in accordance with aspects of the present disclosure; and FIG. 4D illustrates a front end view of the deck of the storage rack in accordance with aspects of the present disclosure;

(5) FIG. 5A illustrates a top plan view of a system comprising a deck of a storage rack positioned on three formed support members in accordance with aspects of the present disclosure; FIG. 5B illustrates a cross sectional view of the deck and one of the three formed support members in accordance with aspects of the present disclosure; and FIG. 5C illustrates a front end view of the deck positioned on three formed support members in accordance with aspects of the present disclosure;

(6) FIG. 6 illustrates a front end view of a second embodiment of a system comprising a deck of a storage rack positioned on three formed support members in accordance with aspects of the present disclosure; and

(7) FIG. 7 illustrates a front end view of a third embodiment of a system comprising a deck of a storage rack positioned on three formed support members in accordance with aspects of the present disclosure;

(8) FIG. 8 is a perspective view of a support member in accordance with a preferred embodiment of the invention;

(9) FIG. 9 is a top view of the support member of FIG. 8;

(10) FIG. 10 is a side view of the support member of FIG. 8;

(11) FIG. 11 is a front end view of the support member of FIG. 8;

(12) FIG. 12 is a perspective view of a support member in accordance with another embodiment of the invention;

(13) FIG. 13 is a side view of a support member, bolted to a horizontal support beam and having a deck structure resting thereon, in accordance with an embodiment of the invention;

(14) FIG. 14 is an enlarged partial side view of an end portion of the structure of FIG. 13;

(15) FIG. 15 is a perspective partial cut away view of multiple deck structures supported by multiple support members supporting multiple deck structures, attached to horizontal support beams and supported by vertical columns, in accordance with an embodiment of the invention;

(16) FIG. 16 is an enlarged partial cut away perspective view of the structures depicted in FIG. 15;

(17) FIG. 17 is a partial cut away side view of the structure of FIG. 15;

(18) FIG. 18 is a side view of a deck structure, formed in accordance with another embodiment of the invention; and

(19) FIG. 19 is a side view of the deck structure of FIG. 18, on a support member and mounted to a pair of horizontal beams.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(20) 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.

(21) 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.

(22) Warehouse support structures are commonly used to support heavy loads of 3000 pounds and more. Some are fastened to the inside surface of a horizontal support beam attached to a vertical column. A structural support member in accordance with the invention can span the horizontal support beams and support a platform, such as a mesh platform. The support member can be an inverted formed U or an angle beam. The angle beam should have an attachment bracket secured to each end, at a height to permit the platform to have the same height as the horizontal beam. The mesh platform should nest in the inside surface of the horizontal beam, between the support member and the beam.

(23) The support beam can have a central section having a first end and a second end and an attachment portion extending past and downward from the first or second end. The central section can have a L-shaped cross section, with a top wall extending horizontally from a vertex and a side wall extending vertically from the vertex at a right angle to the top wall. The vertical wall can have a length terminating at the first or second end of the central portion and the attachment portion can comprise an attachment portion of the top wall, at least at the first end of the central section.

(24) In one embodiment of the invention, the top wall can extend past the length of the vertical wall and deflect downward from a plane of the top wall at a first bend and deflects further downward at a second bend, such that after the second bend, the portion of the top wall extending past the first end of the central section extends vertically downward at a right angle to the top wall. At least one bolt receiving holes should be is formed through the attachment portion. A mesh platform can rest on the top wall, the platform having a main portion parallel to the plane of the top wall and edges that curl down from the plane of the top wall and conform to the attachment portion.

(25) The support member can be secured to a horizontal C-beam having a concave surface defined by a top flange, a vertical wall and a bottom flange, wherein the connection portion conforms to the shape of a surface of the top flange and vertical wall of the C-beam faces the connection portion. A bolt can extend, in sequence, through the C-beam, the edge of the mesh platform and the connection portion.

(26) Reference will now be made in detail to the exemplary embodiments of the present disclosure, which are illustrated in the accompanying drawings.

(27) FIG. 1 illustrates a first embodiment of a formed support member of a storage rack in accordance with aspects of the present disclosure. The formed support member 100 comprises a downwardly facing U-shaped body 110 elongated in an axial direction to form a supporting load bearing surface 101. A first end 102 extended from a central section of the U-shaped body in one direction along the axis and has a curved portion to substantially conform to the internal concavity of a horizontal supporting beam and a substantially flat first engaging end 103 with at least one hole 104. On the opposite direction of the first end 102, a second end 105 extends from the central section of the U-shaped body in an opposite direction along the axis and also has a curved portion to substantially conform to the internal concavity of another horizontal supporting beam and a substantially flat second engaging end 106 being with at least one hole 107.

(28) The length l of the formed support member 100 is defined by the shortest distance between the first engaging end 103 and second engaging end 106. The length l is in the range of from 20 to 44 inches, preferably, from 30 to 40 inches. The length l can be shorter or longer than the specifically recited ranges depending on the dimensions of the storage rack.

(29) The width w of the first engaging end 103 and the width w′ of the second engaging end 106 are preferably in the range of from 3 to 5 inches. The width w and w′ can be shorter or longer than the specifically recited ranges depending on the dimensions of the storage rack, the weight of the load, the material of the formed support member and other unrecited factors.

(30) The height h of the first engaging end 103 and the height h′ of the second engaging end 106 are in the range of from 1 to 4 inches. The height h and h′ can be shorter or longer than the specifically recited ranges depending on the dimensions of the storage rack, the weight of the load, the material of the formed support member and other unrecited factors.

(31) FIG. 2 illustrates a second embodiment of a formed support member of the storage rack in accordance with aspects of the present disclosure. The specific dimensions of the formed support member are provided in FIG. 2A, which is a top view, FIG. 2B, which is a front view and FIG. 2C, which is a side view. In particular, the length l of the formed support member can be 38 to 42 inches. In one example, the length is 41 3/16 inches. The width w of the first engaging end 103 can be 2.5 to 4 inches. In one example, 3¼ inches. The height h of the first engaging end 103 can be 1.5 to 2.5 inches, in one example, 1⅞ inches.

(32) FIG. 3 illustrates a third embodiment of a formed support member of the storage rack in accordance with aspects of the present disclosure. The specific dimensions of the formed support member are provided in FIG. 3A, which is a top view, FIG. 3B, which is a front view and FIG. 3C, which is a side view. In particular, the length l of the formed support member is 41 3/16 inches, the width w of the first engaging end 103 is 3¼ inches, and the height h of the first engaging end 103 is 2⅜ inches.

(33) FIG. 4A illustrates a top view of a deck structure 200, in the form of a mesh of thick wires for a storage rack in accordance with aspects of the present disclosure. Deck 200 comprises a plurality of evenly spaced parallel rods (e.g., thick wires), for example, 211, 212, 213, etc., that are substantially parallel to the formed support members (not shown) and a plurality of evenly spaced perpendicular rods, for example, 221, 222, etc., that are substantially perpendicular to the formed support members (not shown). The perpendicular rods are positioned underneath the parallel rods to rest on the formed support members, with the parallel rods thereon. The intersections of the parallel rods and the perpendicular rods may be welded or joined by any other conventional methods. The perpendicular rods shown in FIG. 4A can have a length of 46⅛ inches.

(34) FIGS. 4B and 4C both illustrate front views of deck 200. FIG. 4D illustrates a side view of deck 200. As shown in FIG. 4B, both ends of the parallel rods 213 are bent to extend downwardly to form a curved shape and substantially conform to the internal concavity of a horizontal supporting C-beam or I-beam (not shown) and the curvature of a formed support member (not shown) so that at least a portion of the ends of the parallel rods are snugly fitted between the horizontal supporting beam and the connection ends of the formed support member. The perpendicular rods, for example, 221 and 222, are positioned underneath the parallel rod 213.

(35) As shown in FIG. 4D, deck 200 further comprises a set of two or three (or otherwise) fastening rods, for example, 231, 232 and 233, affixed on both ends of the parallel rods. The fastening rods 231, 232 and 233 are substantially parallel to the perpendicular rods, for example, 221, and substantially perpendicular to the parallel rods, for example, 211, 212 and 213. The fastening rods are spaced to fit bolts of various sizes through the gaps therebetween. As shown in FIG. 4B, the distance between the fastening rods on both ends of a parallel rod is 41 3/16 inches.

(36) FIG. 5A illustrates a top view of a system comprising deck 200 positioned on three formed support members 100 in accordance with aspects of the present disclosure. Deck 200 is positioned on three evenly spaced formed support members 100 as described above.

(37) FIG. 5B illustrates a cross sectional view along plane “A” of deck 200 and one of the three formed support members 100 in accordance with aspects of the present disclosure. Both ends of the parallel rods 214 extend downwardly to form a curvature shape and substantially conform to an internal concavity 311 or 321 of a horizontal supporting beam 310 or 320, respectively, and the curvature of formed support member 100, so that at least a portion of the end of the parallel rods are snugly fitted between horizontal supporting beam 310 and 320 and connecting ends of formed support member 100.

(38) As shown in FIG. 5B, parallel rods, for example, 214, may comprise a downward slope in a representative length of 2½ inches, so the top surface of the horizontal supporting beams 310 and 320 and the top surface of the parallel rods, for example, 211, 212, 213 and 214, of the deck 200, altogether form a flat surface to support the loads. Since the formed support members 100 are securely fastened and protected by the deck 200 and the horizontal supporting beams 310 and 320, the system claimed herein is structurally steady and does not interfere with the operations of loading and unloading.

(39) The deck is configured such that the upper storage surface formed by the parallel rods is substantially in the same plane as an upper surface of the horizontal support member.

(40) FIG. 5C illustrates a front end side view of the deck being positioned and supported by three formed support members 100 in accordance with aspects of the present disclosure. The perpendicular rods, for example, 221, are substantially in contact with supporting surface 101 of formed support members 100 so that the formed support member provides sufficient support to the deck 200 above.

(41) As shown in FIG. 5C, all three formed support members 100 have one hole 104, and deck 200 has three fastening rods 231, 232 and 233. The holes 104 on the formed support members 100 are aligned with the bolt receiving space between fastening rods 232 and 233 to receive a bolt therethrough to fasten member s 100 to a horizontal support beam, not shown.

(42) FIG. 6 illustrates a front end side view of a second embodiment of a system comprising a deck of a storage rack positioned on three formed support members 100 in accordance with aspects of the present disclosure. In this embodiment of the system, holes 104 on formed support members 100 are aligned with the space between fastening rods 231 and 232.

(43) FIG. 7 illustrates a side view of a third embodiment of a system comprising a deck of a storage rack positioned on three formed support members in accordance with aspects of the present disclosure. In this embodiment of the system, the holes on the formed support members are aligned with the space between fastening rods 232 and 233.

(44) The formed support member 100 may comprise one, two or three (or more) holes on the first engaging end and the second engaging end to accommodate different sized horizontal supporting beams and decks so that once a storage surface deck is positioned above one or more formed support members, at least one hole on the engaging ends of the formed support member is aligned with a space between two adjacent fastening rods for insertion of a bolt. Similarly, the deck may comprise a set of two, three, four or more fastening rods on both ends of the parallel rods to accommodate different sized horizontal supporting beams and formed support members, so that once a deck is positioned above one or more formed support members, at least one space between two adjacent fastening rods is aligned with a hole on the engaging ends of the formed support member.

(45) In further embodiments of the invention, a formed support member having two holes on the engaging ends and a deck being assembled in accordance with aspects of the present disclosure is provided. The holes are configured to permit proper attachment to and alignment with either a 3″ horizontal support member or a 4″ horizontal support member, while maintaining proper support for the deck.

(46) In a further embodiment of the formed support member of the present invention, the width w of the first engaging end 103 and the width w′ of the second engaging end 106 are reduced so that the entire first engaging end 103 and the entire second engaging end 106 are positioned between two parallel rods, for example, 215 and 216 in FIG. 5A, so that any possible rotation introduced during the fastening process would be avoided or at least partially reduced.

(47) The formed support member and storage surface grating can be fabricated from suitable materials, including, but not limited to, metal(s), including alloy(s), or combinations thereof, etc. Suitable metals include aluminum, copper, iron, tin, lead, titanium, zinc and etc. Suitable alloys including steel, solder, brass, pewter, duralumin, bronze, amalgams and etc. The formed support member may be fabricated from a single material or a combination of materials, including, but not limited to, the above exemplary materials, to achieve various desired characteristics such as strength, rigidity, performance and durability. Preferred support members are formed from a single piece of metal material.

(48) The present disclosure is advantageous because the ends of the grating and the ends of the underneath formed support members are embraced by the horizontal supporting beams of a storage rack. As shown in FIG. 3, the exposed portion of the grating forms a flat supporting surface substantially in the same plane defined by the top surface of the horizontal supporting beams. Problems of formed support members being interfere with the loading and unloading processes are reduced, thereby improving the stability and reliability of the storage rack.

(49) A heavy-duty support member 800 in accordance with another embodiment of the invention is shown generally in FIGS. 8-11. Heavy-duty support member 800 is more conveniently constructed to support heavier loads and span greater distances between horizontal support beams, as compared to formed supporting member 100. Support member 800 has the cross section of an angle bracket and a central support section 810 in the form of an angle beam. Central section 810 includes a horizontal top wall 815 and a vertical side wall 817. Top wall 815 defines a substantially flat, horizontal load bearing surface and side wall 817 depends vertically, and a right angle, from top wall 815. The cross section of central section 810 has the shape of an “L”, with top wall 815 meeting side wall 817 at a vertex 816.

(50) Support member 800 includes a connection bracket 820 at both ends thereof, to secure support member 800 to a horizontal support beam, as illustrated, for example, in FIGS. 13-15. Connection bracket 820 has the shape and construction of an angle bracket, and includes a connection arm 821 connected to an engagement arm 823, joined at a bracket vertex 822. Connection arm 821 of connection bracket 820 can be welded or otherwise attached to central section 810.

(51) Preferably, connection arm 821 is joined to an outer surface of side wall 817. An upper edge 825 of connection bracket 820 should be offset from the top surface of horizontal top wall 815. In addition, connection bracket 820 should be offset from an end 819 of central section 810 with an offset gap 840. This permits heavy-duty support member 800 to nest in the concave recess of a C-beam (or I-beam) with the top flange of the C-beam extending into the gap, so that engagement arm 823 can be flat with the horizontal wall of the C-beam and top wall 815 can be on the same plane as the top flange of the C-beam. One or more bolt receiving holes 829 is provided to secure support member 800 to the horizontal support beam.

(52) Another embodiment of the heavy-duty support member is shown generally as support member 801 in FIG. 12. Support member 801 includes a top wall 815 meeting at side wall 817 at a vertex 816, as in support member 800. However, rather than attach a separate connection bracket 820, support member 801 includes a formed engagement end 830.

(53) Support members 800 and 801 are preferably 30 to 50 inches long, preferably 36-48 inches long or more. Lengths of 4 to 5 feet and longer are possible.

(54) Engagement end 830 is formed by slicing the ends of vertex 816 to form a horizontal flap 831 of top wall 815 and a vertical flap of side wall 817. The vertical flap can be trimmed, as in FIG. 12 or bent out of the way. Horizontal flap 831 is initially bent downward, to conform to the inner concave surface of the C-beam where horizontal flap 831 extends from top wall 815 and is bent further, to form an engagement surface 832 with a bolt receiving hole 833 therethrough. engagement surface 832 is formed to conform to the flat vertical wall of the C-beam, to join heavy-duty support member 801 to the horizontal support beam.

(55) FIGS. 13 and 14 depict a support member 800 having a storage surface deck structure 250 thereon. Deck structure 250 includes an array of lower perpendicular rods 260, with an array of upper parallel rods 270 perpendicular to rods 260. Rods 260 can be welded or otherwise joined to rods 270 in form a rectangular mash to support pallets, cartons and other merchandise thereon. Each end 280 of deck 250 is bent downward, to conform to the inner concave shape of a horizontal support beam 850. Ends 280 of deck 250 include a plurality of engagement rods 261, 262 and 263. A bolt 270 is inserted through a bolt receiving hole through horizontal support beam 850, in a bolt receiving space between two of the engagement rods 261 and 262 and through bolt receiving hole 829 through engagement bracket 820. The various parts should be sized, arranged and configured, so that an upper surface of parallel rods 270 conforms to an upper surface 851 of horizontal support beam 850. This will help facilitate loading and unloading of objects from deck 250.

(56) All a fully assembled storage system 900 is shown generally in FIGS. 15-17. Storage system 900 includes a plurality of vertical columns 910 which are stabley secured to a substrate floor surface. A plurality of horizontal beams 850 are bolted, or otherwise secured to columns 910. A plurality of support members 800 are secured to horizontal beams 850. A deck structure 250′ rests on support members 800. The ends of deck structure 250′ bend downward, and fit between engagement ends 823 of support members 850. A bolt 270 extends through a bolt receiving hole through horizontal beam 850, between engagement rods 261 and 262 of deck 250′ and through hole 829 on the engagement surface 823 of engagement bracket 820.

(57) Alternative embodiments of support members having two holes on the engaging ends and a deck being assembled in accordance with aspects of the present disclosure. The holes can be configured to permit proper attachment to and alignment with either a 3, 3.5, or 4 inch horizontal support member, while maintaining proper support for the deck.

(58) In a further embodiment of the formed support member of the present invention, the width w of the first engaging end and the width w′ of the second engaging end are reduced, so that the entire first engaging end 10 and the entire second engaging end are positioned between two parallel rods, for example, 215 and 216 in FIG. 5A, so that any possible rotation introduced during the fastening process would be avoided or at least partially reduced.

(59) The formed support member and grating can be fabricated from suitable materials, including, but not limited to, metal(s), alloy(s), or combinations thereof, etc. Suitable metals include aluminum, copper, iron, tin, lead, titanium, zinc and etc. Suitable alloys including steel, solder, brass, pewter, duralumin, bronze, amalgams and etc. The formed support member may be fabricated from a single material or a combination of materials, including, but not limited to, the above exemplary materials, to achieve various desired characteristics such as strength, rigidity, performance and durability.

(60) Referring to FIG. 18, a security deck 1800 is shown in side view. Security deck 1800 is similar to deck 200, but includes a safety stop 1801 to help prevent containers from being inadvertently pushed off a rear end of deck 1800. As with deck 200 the front end of the grating and the ends of formed support members 100, on which it rests, are embraced by a front horizontal supporting beam 1310 and a rear horizontal supporting beam 1320 of a storage rack. As shown in FIG. 18, the exposed top portion of the grating forms a flat supporting surface defining a plane A1, substantially in the same plane defined by a top surface of the horizontal supporting beams 1310 and 1320.

(61) Deck 1800 comprises a plurality of evenly spaced parallel rods (e.g., thick wires), for example, a rod 1814, that are substantially parallel to formed support members 100, shown in FIG. 19 and a plurality of evenly spaced perpendicular rods, for example, 1822 that are substantially perpendicular to formed support members 100. Perpendicular rods 1822 are positioned underneath parallel rods 1814 and rest on formed support members 100, with parallel rods 1814 thereon. The intersections of parallel rods 1814 and perpendicular rods 1822 may be welded or joined by any other conventional methods. The perpendicular rods shown in FIG. 18 can have a length of about 44-48 inches, preferably about 46⅛ inches.

(62) As shown in FIG. 18, front ends 1850 of the parallel rods 1814 are bent to extend downwardly, to form a curved shape and substantially conform to the internal concavity of front horizontal supporting C-beam or I-beam 1310 and the curvature of formed support member 100, so that at least a portion of the ends of parallel rods 1814 fit snugly between horizontal supporting beam 1310 and the front connection end of formed support member 100.

(63) Deck 1800 further comprises a set of two or three (or otherwise) fastening rods 1831, 1832 and 1833, affixed on the front end of parallel rods 1814. The fastening rods can also be fixed to rear end 1860. Fastening rods 1831, 1832 and 1833 are substantially parallel to perpendicular rods 1822. Fastening rods 1831, 1832 and 1833 can be on the opposite side of parallel rods 1814 as is perpendicular rods 1822. Fastening rods 1831, 1832 and 1833 are spaced to fit bolts of various sizes through the gaps therebetween. The rear end fastening rods can be on the same side of parallel rods 1814 as are perpendicular rods 1822. Thus, the front and rear fastening rods should both be located on the outside surface of deck 1800.

(64) FIG. 19 illustrates a side view along of deck 1800 and one of the e.g., three formed support members 100 in accordance with aspects of the present disclosure. Rear ends 1860 of parallel rods 1814 extend upwardly to form safety stop 1800. Rear end 1860 can be shaped as the mirror image of front end 1850.

(65) It is preferred that plane A1 be substantially even with the top surface of front beam 1310. Front end 1850 initially deflects downwards at an angle A2, to fit under the top flange of front beam 1310. Front end 1850 then deflects downward, so as to be about perpendicular to plane A1 and nest against the web of front beam 1310.

(66) Rear end 1860 first deflects upwards at an angle A3, to clear the top flange of rear beam 1320. The first deflection can be about 5°-40°, preferably about 5°-30°, more preferably about 10°-20°. Angles A2 and A3 can be about the same. Rear end 1860 then deflects at a second inflection angle A4, to be about substantially perpendicular to plane A1, less angle A3. Second deflection angle A4 should be at an angle of about 85° to 35°, preferably about 85° to about 45°. In another embodiment of the invention, safety stop 1801 can extend at least about 2 inches, preferably up to about 10 inches, more preferably about 2-6 inches rearwards from rear beam 1320. In another embodiment of the invention, safety stop 1801 can extent up to 24 inches or higher to act as a partition and separate sections of the loading surface.

(67) Parallel rods 1814 may comprise a downward slope in a representative length of about 2-3 inches, so the top surface of front horizontal beams 1310 the top surface of parallel rods 1814 of deck 1800, altogether form a flat surface to support the loads. The deck is configured such that the upper storage surface formed by the parallel rods is substantially in the same plane as an upper surface of the horizontal support member.

(68) Deck 1800 can be formed from various materials. Steel wire is particularly suitable. Wires in sizes at least as heavy as 7 or 8 gauge are suitable. Preferred decks are formed from wires of about 2-7 gauge, more preferably, 3-5 gauge and most preferably, 4 gauge.

(69) While the above description contains many specifics, these specifics should not be construed as limitations of the invention, but merely as exemplifications of preferred embodiments thereof. Those skilled in the art will envision many other embodiments within the scope and spirit of the invention as defined by the claims appended hereto.