STORAGE SURFACE ASSEMBLY

This application claims priority to the filing date of U.S. Application Serial No.

11/269,654, filed November 9, 2005, and is a Continuation-In-Part of application Serial

No. 10/460,309 filed June 13, 2003, both of which are incorporated herein in their

entirety by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[1] This invention relates to a storage surface assembly for use as a shelf for

holding storage items in industrial/ commercial applications/environments.

2. Background of the Related Art

[2] Storage shelves used in an industrial/commercial environment must often

bear heavy loads while still maintaining their structural integrity, as well as resist the

twisting and buckling forces generated when storage items are loaded, unloaded, or

moved. These industrial storage shelves are also subjected to fire codes requiring some

amount of "open area" along the surface of the shelf, dictated in most cases by the

particular environment in which they will be used, as well as the types of items to be

stored.

[3] The "open area" required by fire codes is typically 50% of the surface area

of the shelf. This open area requirement was imposed to allow a fire in the storage

area to be more efficiently contained and extinguished, thus minimizing damage to

storage items. More specifically, a shelf with an adequate amount of open area allows a

fire initiated on a lower shelf to move vertically up the storage rack, towards the

sprinkler, allowing heat to dissipate more quickly and activating the sprinklers before

the fire has gained significant intensity. Closed shelves (shelves with little to no open

area), which may provide adequate load capacity and structural integrity, would, on

the other hand, form an enclosed space between shelves, allowing a fire to build in

intensity in that enclosed space, spread horizontally to a neighboring rack of shelves,

and also delay deployment of the sprinkler system, rendering the sprinkler system

significantly less effective in containing and extinguishing the fire. This 50% open area

requirement poses a unique challenge in providing shelves with adequate structural

integrity at a reasonable cost, while still meeting this open area requirement. Current

solutions, such as those discussed below, are not adequate.

[4] Slatted wooden decking, although easily and inexpensively manufactured,

has significant disadvantages in that it is less durable and more susceptible to

deformation than steel, and more likely to break under continued loading or changing

environmental conditions. Its most significant disadvantage is that it is highly

flammable.

[5] Wire mesh decking is a commonly used shelving solution in

industrial/commercial applications. Wire mesh meets the 50% open area requirement,

but, as wire mesh is simply laid across a series of cross bars, it remains unsupported

across a majority of its load-bearing surface, and thus deforms easily. Further, if one of

the support bars is damaged, it cannot be repaired or replaced without removal of the

entire wire mesh, most likely resulting in replacement of the entire deck as repair

would not be cost effective. Additionally, due to the nature of the surface of wire

mesh, especially after it has deformed, it is difficult to load/unload/move storage items

without damaging the storage items and/or the wire mesh, as the mesh tends to catch

on the storage items, producing rips, punctures, or impressions. Wire mesh decks are

not easily manufactured or shipped, making them a more costly, less efficient shelving

solution.

[6] U.S. Patent No. 5,279,431 to Highsmith et al. discloses a storage rack

with storages surfaces formed by crossbars with tangs extending from the ends which

are then inserted into corresponding slots in the side beams. However, Highsmith's

design is complicated, difficult and costly to manufacture, and the shelving system

must be used with Highsmith's racking system and cannot be readily adapted for use

in other racking systems. Further, as the bulk of the load on the storage surface is

carried by a very small tang at the end of the crossbar, Highsmith's design cannot be

used in commercial/industrial applications, where shelves must bear heavy loads while

maintaining their structural integrity.

[7] Likewise, U.S. Patent No. 5,628,415 to Mulholland also discloses a

storage rack with safety bars fitted to support beams by mating tabs and slots.

Mulholland's design is complicated, difficult and costly to manufacture, and is for an

entire racking system whose shelves cannot be readily adapted for use with other

racking systems.

[8] U.S. Patent No. 5,199,582 to Halstrick discloses a storage rack which uses

a corrugated plate to form each shelf. Although Halstrick's design incorporates holes

in the corrugated sheet to allow for a very limited amount of open area, this design

could not meet the 50% open area requirement with out affecting the structural

integrity of the shelf.

[9] U.S. Patent No. 6,401,944 to Kircher et al. discloses a storage rack similar

to Halstrick's which does meet the 50% open area requirement. However, there are

several disadvantages associated with Kircher's design. Kircher's corrugated deck is

expensive to manufacture and ship, increasing cost to the user. If not properly secured

in the rack, the deck elements can spread over time due to the load applied by the

storage items, forcing the rack to carry more that its design load, thereby

compromising the rack's structural integrity. Similar to wire mesh, the holes, unless

properly finished, tend to shred storage items when they are loaded, unloaded and

moved.

[10] The above references are incorporated by reference herein where

appropriate for appropriate teachings of additional or alternative details, features

and/or technical background.

SUMMARY OF THE INVENTION

[11] An object of the invention is to solve at least the above problems and/or

disadvantages and to provide at least the advantages described hereinafter.

[12] According to the invention, therefore there is provided a storage surface

assembly for use as a shelf for holding storage items in industrial or commercial

environments. Some amount of the surface area of the storage surface assembly

remains open in order to provide for adequate circulation of air, heat dissipation, and

water flow, and meet current fire code requirements. The open area of the storage

surface assembly would typically be at least 50% in order to comply with current fire

codes. However, as will become apparent in the discussion that follows, the storage

surface assembly may be adjusted to meet a variety of open area requirements, and is

not limited to a 50% open area.

[13] Additional advantages, objects, and features of the invention will be set

forth in part in the description which follows and in part will become apparent to

those having ordinary skill in the art upon examination of the following or may be

learned from practice of the invention. The objects and advantages of the invention

may be realized and attained as particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[14] The invention will be described in detail with reference to the following

drawings in which like reference numerals refer to like elements wherein:

[15] Figure 1 is a perspective view of a storage surface assembly according to

an embodiment of the invention;

[16] Figures 2A-2B are perspective views of extension members employable in

a storage surface assembly according to an embodiment of the invention;

[17] Figure 2 C is a cross sectional view of the extension members of Figures

2A-2B;

[18] Figure 2D is a perspective view of an alternative extension member

according to an embodiment of the invention;

[19] Figure 2E is a perspective view of another alternative extension member

according to an embodiment of the invention;

[20] Figures 2F-2H are cross sectional views of stacked traverse members

according to embodiments of the invention;

[21] Figures 2I-2M are perspective views of alternative extension members and

alternative traverse members according to embodiments of the invention;

[22] Figure 2N is a side view of the traverse member shown in Figure 2M

secured in the extension member shown in Figure 2M;

[23] Figure 3A is a perspective view of a traverse member employable in a

storage surface assembly according to an embodiment of the invention;

[24] Figure 3B is a cross sectional view of the traverse member of Figure 3 A;

[25] Figure 3G is a cross sectional view of a traverse member, in accordance

with an embodiment of the invention;

[26] Figures 4A-4S are cross sectional views of alternatively shaped traverse

members according to embodiments of the invention;

[27] Figure 5 is a top view of a storage surface assembly according to an

embodiment of the invention;

[28] Figures 6A-6B are top views of a storage surface assembly according to an

embodiment of the invention showing alternate grouping configurations of traverse

members;

[29] Figure 7 is a front view of a rack beam assembly according to an

embodiment of the invention incorporating a storage surface assembly according to

the invention; and

[30] Figure 8 is a perspective view of the rack beam assembly of Figure 7.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[ilj Jhigure 1 is a perspective view of a storage surface assembly according to

an embodiment of the invention. The storage surface assembly 100 of Figure 1 is

constructed of a plurality of traverse members 20 attached to extension members 30 at

attachment members 40 to form a surface area 36. As shown in Figure 5, at least a

portion of the traverse members 20 are spaced apart from one another to form open

spaces 50. In order to meet current fire code requirements and in order to provide for

adequate circulation of air, heat dissipation, and water flow, at least 50% of the surface

area 36 remains open via the open spaces 50 formed between the traverse members 20.

[32] It is well understood by one skilled in the art that the amount of surface

area 36 that remains open can be either increased or decreased based on the number of

traverse members 20 attached to a particular pair of extension members 30, as well as

the positioning of the traverse members 20 along the extension members 30. In this

manner, the storage surface assembly 100 can be adapted to meet a variety of open area

requirements.

[33] In the embodiment of Figure 1, the extension members 30 comprise angle

irons; however, other shapes and materials may also be appropriate. The number of

traverse members 20 used in the construction of the storage surface assembly 100 can

be adjusted to suit, for example, the size and load bearing capability required for a

particular application. However, the open air space must remain at least 50% for the

above described reasons.

[34] Figures 2A-2B are perspective views and Figure 2C is a cross sectional

view of an extension member 30 employable in a storage surface assembly in

accordance with an embodiment of the invention. The extension members 30 of the

embodiment of Figures 2A-2C comprise angle irons forming an angle θ of 90 degrees;

however, other angles may also be appropriate, depending on the particular

application. Likewise, the length a, width b and height c of the extension member 30

can be varied as necessary, depending, for example, on a particular application's size

and load bearing requirements.

[35] Figure 3 A is a perspective view and Figure 3B is a cross sectional view of

a traverse member 20 employable in a storage surface assembly in accordance with an

embodiment of the invention. The exemplary traverse member 20 shown in Figures

3A-3B are formed in a ' ' shape, with a bottom width f larger than a top width e;

however, the length d, top width e, bottom width f, and height g can be varied as

necessary", depending on, for example, a particular application's size and load bearing

requirements. For example, in the traverse member 20 shown in Figure 3C, the

bottom width is f substantially equal to the top width e, with the attachment members

40 curved inward. Likewise, a number of different cross sectional shapes, such as those

shown in Figures 4A-4S, may also be appropriate for the traverse members 20.

[36] As shown in Figure 5, the traverse members 20 are attached to the

extension members 30 at attachment members 40. The attachment members 40 serve

to both fix the traverse members 20 in position along the extension members 30, and

also to inhibit spreading of the traverse members 20 due to the load applied by a

storage item and subsequent loss of load bearing capability. The traverse members 20

which are used in fabricating a single storage surface assembly must not necessarily be

of the same cross sectional shape, and traverse members 20 of different cross sectional

shapes, such as, for example, combinations of those shown in Figures 4A-4S, may be

combined to form a single storage surface assembly.

[37] The traverse members 20 and extension members 30 can be made of a

variety of different materials. Fabrication material may be selected based on, for

example, load bearing requirements and the operating environment for a particular

application, as well as cost. For example, in a storage application where humidity and

environmental degradation are factors, both the traverse members 20 and extension

members 30 may be made of a galvanized steel to inhibit material breakdown due to

the environmental factors and subsequent loss of structural integrity. Likewise, in a

storage application where cleanliness and appearance are factors, such as in a

commercial kitchen, both the traverse members 20 and extension members 30 may be

made of a stainless steel. Other materials may also be appropriate. Traverse members

20 and extension members 30 may not necessarily be fabricated from the same

material. However, attachment methods and environmental effects should be

considered when selecting dissimilar materials for the traverse members 20 and

extension members 30.

[38] In certain embodiments, the attachment members 40 may extend

outward from the main body of the traverse member 20, such as those shown in, for

example, the embodiments of Figures 4A ₅ 4E, 41 and 4M, and the traverse member 20

is attached to the extension member 30 at the attachment member 40. In other

embodiments, the attachment members 40 may extend inward from an outer surface

of the traverse member 20 towards an inner center of the main body of the traverse

member 20, such as those shown in, for example, the embodiments of Figure 4B, 4F

and 4J. In still other embodiments, one attachment member 40 may extend outward

from the main body of the traverse member 20, while the other attachment member

40 extends inward, such as those shown in, for example, the embodiments of Figures

4C-4D, 4G-4H, and 4K-4L.

[39] There are numerous ways to effectively attach the traverse members 20

to the extension members 30. Some of the methods of attachment well known to

those skilled in the art can include, but are not limited to, welds, screws, rivets, and the

like. Attachment of the traverse members 20 to the extension members 30 to form a

storage surface assembly is not necessarily limited to a single method of attachment

within a single storage surface assembly. A combination of attachment methods may

be used in assembling a single storage surface assembly, based on the requirements

dictated by a particular application.

[40] Additionally, with any of the above attachment methods, individual

traverse members 20 can be removed from the extension members 30 and replaced

with new/repaired traverse members 20 without complete disassembly of the storage

surface assembly 100 or replacement of all traverse members 20 while still maintaining

the 50% open area. This allows for cost effective repair of the storage surface assembly

100, and a potentially longer term of use than related art systems.

[41] In yet another embodiment, the extension members 30 are formed as

shown in Figure 2D with a recess 35 which is designed to mate with an end of the

traverse member 20 and allow for slidable assembly of the traverse member 20 into the

recess 35 of the extension member 30. In this manner, movement of the traverse

member 20 along the extension member 30, as well as spreading of the traverse

member 20 due to a load applied by a storage item is prevented by the sides of the

recesses 35 rather than by the attachment member 40.

[42] The extension member 30 can also be formed as shown in Figure 2E,

with slots 36 positioned along a horizontal portion of the extension member 30 and

corresponding to the attachment members 40 of the traverse member 30, allowing for

slidable assembly of a single traverse member 20 such as those shown in, for example,

Figures 4A-4M, into the slots 36 of the extension member 30, or a "stack" of traverse

members as shown in, for example, Figures 2F-2H, and discussed below. A flat plate

31 is then attached to a bottom surface of the extension member 30, with the

attachment members 40 positioned therebetween, thus securing the traverse members

20 in place.

[43] The spacing of the slots 36 along the horizontal portion of the extension

member 30 may be adapted to meet the requirements of a number of different storage

applications, and the slots 36 need not be equally spaced. Additionally, as shown in

Figures 2F-2H, the attachment member 40 of a first traverse member 20 can be placed

on and aligned with an attachment member 40 of a second traverse member 20,

forming a "stack" of attachment members 40. The stacked attachment members 40 of

the first and second traverse members 20 can then be slidably inserted into the slots 36.

Stacked traverse members 20 need not necessarily have the same cross sectional shape

or attachment member 40 orientation. For example, the traverse member 20 shown in

Figure 4A can be stacked with any of the traverse members 20 shown in Figures 4B-

4M and then slidably inserted into slot 36. Likewise, the traverse member 20 shown in

Figure 4B can be stacked with any of the traverse members 20 shown in Figures 4A,

4C-4E, 4G-4I, and 4K-4M, and so on.

[44] Both the single and the stacked slidable attachment methods discussed

above may be employed with a variety of different traverse member 20 combinations,

and traverse members 20 need not all be of the same shape in a single storage surface

assembly.

[45] A snap fit procedure could also be employed in attaching traverse

members to extension members, as shown in Figures 2I-2M. Figure 21 shows a snap fit

extension member 32 with a vertical extension 33 formed along its length, and notches

33a and 33b corresponding to the cross sectional shape of attachment members 23a and

23b of a snap fit traverse member 23 cut into the vertical extension 33 at

predetermined positions along the length of the snap fit extension member 32. When

attachment members 23a and 23b are aligned with notches 33a and 33b, a downward

force applied to the snap fit traverse member 23 would cause the attachment members

23a and 23b to temporarily contract as they pass through the more narrow portion of

the notches 33a and 33b, and return to their original shape once they enter the wider

portion of the notches 33a and 33b, thus securing the snap fit traverse member 23 to

the snap fit extension member 32. A similar procedure would be used to snap fit the

snap fit traverse member 23 to the snap fit extension member 32 shown in Figures 2J-

2L.

[46] Figure 2M shows a snap fit extension member 32 with a vertical

extension 33 formed along its length. Notches 33c and 33d corresponding to the cross

sectional shape of attachment members 23c and 23d of a snap fit traverse member 23

are cut into the vertical extension 33 at predetermined positions along the length of the

extension member 32. Figure 2N shows this snap fit traverse member 23 secured to

this snap fit extension member 32. The notches 33c and 33d are specifically shaped to

accommodate the curved shape of the attachment members 23c and 23d. Each notch

includes a protrusion 33e which engages a corresponding slot 23e formed in the side

wall of the snap fit traverse member 23 as the attachment members 23 c and 23 d are

directed downward into the notches 33c and 33d, thus securing the snap fit traverse

member 23 to the extension member 32, as shown in Figure 2N. Although the

extension members 32 and traverse members 23 shown in Figures 2M-2N include two

protrusions 33e and two corresponding slots 23e formed in each end of each traverse

member 23, it is well understood that these elements could also be effectively secured

with a single protrusion 33e and slot 23e at either one end or each end of the traverse

member 23. Other means of attaching the traverse members to the extension member

may also be appropriate based on the application, materials used, and other factors

which may effect the assembly's performance.

[47] Figure 5 is a top view of a storage surface assembly according to an

embodiment of the invention. The storage surface assembly of Figure 5 includes a

plurality of traverse members 20 extending between two extension members 30. The

traverse members 20 are spaced apart from one another forming open spaces 50. In

Figure 5, the traverse members 20 are shown substantially equally spaced along the

extension members 30. However, the amount of open space 50 between traverse

members 20 may be varied as shown in Figures 6A-6B, and various traverse member

20/open area 50 spacing combinations may be appropriate, based, for example, on the

desired configuration and/or application. For example, the traverse members 20 may ^¬

be grouped, as in the embodiment of Figure 6B, with the open space 50 between

groups in these alternative configurations adjusted to conform to the open area

requirement as necessary. In this manner, the grouping and spacing of traverse

members 20 along the extension members 30 may be adjusted to meet individual user

requirements without redesign of the base components of the storage surface assembly

100.

[48] Figure 7 is a front view of a rack beam assembly according to an

embodiment of the invention incorporating a storage surface assembly according to

the invention. The rack beam assembly of Figure 7 includes a storage surface assembly

100 installed in a set of rack beams 200. The rack beams 200, designed to fit one of

many standard commercial/industrial racking systems, may be specified by the user

and are well known in the industry. Figure 8 is a perspective view of the rack beam

assembly 300. As shown in Figure 8, the rack beam assembly 300 may be installed in a

commercial/industrial racking system 400.

[49] As evidenced by the numerous traverse member configurations,

attachment methods, and grouping/spacing configurations discussed herein, the

various embodiments of the invention provide clear advantages over the related art

with an easily and inexpensively manufactured and distributed shelving solution that

exhibits adequate load bearing capability and structural integrity while still meeting the

50% open area requirement, and which can be easily adapted to meet specific user

needs.

[50] The foregoing embodiments and advantages are merely exemplary and

are not to be construed as limiting the invention. The present teaching can be readily

applied to other types of apparatuses. The description of the invention is intended to

be illustrative, and not to limit the scope of the claims. Many alternatives,

modifications, and variations will be apparent to those skilled in the art. In the claims,

means-plus-function clauses are intended to cover the structures described herein as

performing the recited function and not only structural equivalents but also equivalent

structures.