Note: Descriptions are shown in the official language in which they were submitted.
CA 02793385 2012-10-26
STRUCTURAL ARTICULATION JOINT FOR HIGH DENSITY MOBILE CARRIAGE
BACKGROUND OF THE INVENTION
100011 The present disclosure generally relates to industrial storage
systems and, more
particularly, to a mobile industrial rack system for use in areas having
seismic activity or on
unleveled flooring.
100021 Industrial rack systems are commonly used in storage facilities
to store
products until those products are shipped either directly to a consumer or to
a retailer.
Typically, the industrial racks store loaded pallets that are placed on and
removed from the
racks using a forklift. The industrial racks are spaced from one another in a
manner to form
relatively wide aisles to allow sufficient room for the forklift to load and
remove the pallets.
Since each industrial rack has a fixed position, each industrial rack must
have a dedicated
aisle. Moreover, since each aisle is typically as wide, if not wider than, the
rack itself, more
than half the floor space occupied by the industrial rack system may be
occupied by aisles and
thus not usable for product storage.
[0003] Mobile industrial rack systems, however, are designed to reduce
the number of
fixed aisles and, as a result, increase the amount of floor space used for
product storage.
More particularly, in a typical configuration, a single aisle may be allocated
for the entire
industrial rack system. The position of that single aisle can be changed by
moving the
industrial racks along a track or rail that is mounted or otherwise secured to
the storage
facility flooring, which is typically a concrete slab. While in some
configurations each
industrial rack is moved independently, it is common for back-to-back
industrial racks to be
coupled using a rigid flue spacer connector and moved as a single multi-rack
unit by a single
mobile carriage supporting both racks. To access a forward rack of a given
back-to-back
configuration, the racks are moved such that an aisle is formed immediately
forward of the
back-to-back configuration. To access a rearward rack of the given back-to-
back
configuration, the racks are moved such that an aisle is formed immediately
rearward of the
back-to-back configuration. Mobile industrial rack systems provide nearly
twice the storage
capacity of a similarly sized fixed rack system.
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[0004] Conventional mobile industrial rack systems must roll on
leveled rail such that
the heavy loading of the industrial racks does not create an undesired
imbalance as the racks
are being moved. Thus, in a typical implementation, the existing concrete
floor of a storage
facility, which is generally not level within the specifications required for
the mobile
industrial rack system, must be leveled by applying a thin coat of concrete
material to the
concrete floor. The rails along which the racks move are then anchored through
the thin coat
of concrete material and to the concrete floor. Alternately, footings may be
poured beneath
the concrete floor and the rails anchored to the footings beneath the concrete
floor. A similar
thin coat of concrete material is then poured around the rail to provide a
leveled floor surface.
Grout or similar material is typically placed between the rails and the
concrete floor or
footings. In both instances, measures must be taken to provide a level surface
for the rails
along which the racks move, which are generally quite costly.
[0005] In areas in which there is a relatively high frequency of
seismic activity, rigid
connectors are often required between the two racks of a multi-rack unit to
withstand seismic
activity. The rigid connectors used between the two racks of a multi-rack unit
somewhat
limits the degree to which the floor can be uneven. Thus, a connector that
allows for relative
movement between the two racks of a multi-rack unit increases the use and
availability for the
mobile industrial rack system.
SUMMARY OF THE INVENTION
[0006] The present disclosure is directed to a mobile industrial rack
system usable in
areas having seismic activity. The mobile rack system includes one or more
spaced couplers
positioned between the vertical uprights of adjacent racks of a multi-rack
unit that provide the
structural stability between the racks while still allowing the racks to move
relative to each
other, such as during seismic activity.
[0007] Each coupler used between adjacent racks is formed from three
separate
components that interact and engage each other. The coupler includes a
coupling bracket, a
receiving bracket and a movement bracket. The couplers are each mounted in the
flue space
between adjacent storage racks. The coupling bracket and receiving bracket are
mounted to
the same upright of one storage rack. The coupling bracket includes a coupling
tab that
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passes through movement slots formed in the movement bracket mounted to the
opposite
storage rack. Each of the coupling tabs extends through slots formed in the
receiving bracket.
Each of the coupling tabs receives a removable connector that prevents
separation of the
individual components of the coupler while allowing relative movement between
the
individual components.
[0008] The coupler of the present disclosure forms a structural
articulation joint
between adjacent racks of a mobile industrial rack system. The articulation
joint created by
the couplers provides a strong movement connection between two coupled storage
racks such
that the two storage racks can be considered as a single unit for purposes of
evaluating their
stability when subjected to overturning forces. The coupler allows for
relative movement
between the adjacent racks while still providing the required structural
stability between the
adjacent racks.
[0009] Various other features, objects and advantages of the invention will
be made
apparent from the following description taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The drawings illustrate the best mode presently contemplated of
carrying out
the disclosure. In the drawings:
[0011] Fig. 1 is an isometric view of a representative embodiment of a
mobile
industrial rack system incorporating the features of the present disclosure;
[0012] Fig. 2a is a magnified view of a coupler used to join a pair of
storage racks of
the mobile industrial rack system of Fig. 1;
[0013] Fig. 2b is a perspective view of the coupler similar to the view in
Fig. 2a;
[0014] Fig. 3 is a top view of the coupler shown in Fig. 2;
[0015] Fig. 4 is a rear perspective view of the coupler shown in Fig. 3;
[0016] Fig. 5 is a further magnified view of a retaining pin used to hold
the coupler in
the coupled condition;
[0017] Figs. 6a-6c show the coupling bracket that forms part of the
coupler;
[0018] Figs. 7a-7c illustrate the movement bracket that forms part of the
coupler; and
[0019] Figs. 8a-8c illustrate the receiving bracket that forms part of the
coupler.
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DETAILED DESCRIPTION OF THE INVENTION
[0020] Fig. 1 illustrates a mobile industrial rack system 10 that includes
a series of
industrial storage racks 12 that are movable along a series of spaced and
parallel rails (not
shown) that are mounted within the floor of a building. In the embodiment
shown, the
industrial storage racks 12 are arranged in pairs so as to form multiple multi-
rack units 16,
with each multi-rack unit 16 having a forward rack 12a and a rearward rack
12b, wherein the
multi-rack unit 16 is movable as a single unit. Each multi-rack unit 16 is
associated with a
control interface that controls movement of the industrial storage racks 12
along the rails
mounted to the building floor.
[0021] As illustrated in Fig. 1, each end of the individual racks 12
includes a pair of
vertical uprights 18 that are joined to each other by a series of braces 20.
The series of braces
20 and uprights 18 create a relatively rigid end frame 22 for each of the
racks 12. Although
not illustrated in Fig. 1, shelving is positioned between the pair of spaced
end frames 22 to
support items along each of the individual racks 12.
[0022] The multi-rack unit 16 shown in Fig. 1 is driven by a single motor
24 that
operates to rotate a series of support wheels for the unit 16. In this manner,
the entire multi-
rack unit 16 is movable along the spaced rails mounted to the building floor.
[0023] As illustrated in Fig. 1, the lower frame members 26 of each storage
rack 12
are joined to each other by a series of connecting beams 28. Although the
lower end of each
rack 12 is joined by the connecting beams 28, a series of couplers 30 are used
to join adjacent
uprights 18 of the pair of storage racks 12. The couplers 30 shown in Fig. 1
are configured
and designed to allow the individual racks 12 to move relative to each other
to provide an
articulating structural connection in the flue space 32 between the individual
racks 12 of the
multi-rack unit 16. The couplers 30 are each configured to provide a joint
between the pair of
racks 12a and 12b to provide a strong connection between the racks while
allowing the racks
to move relative to each other. The relative movement between the two racks
12a and 12b
allows the unit to compensate for either an uneven floor or seismic
acceleration that may take
place during an earthquake. The use of the couplers 30 is particularly
desirable when the
mobile industrial rack system 10 of the present disclosure is installed in a
seismic region.
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[0024] In the embodiment illustrated in Fig. 1, four separate couplers
30 are
positioned in the flue space 32 between the adjacent racks 12a, 12b that form
part of the
coupled unit 16. However, it should be understood that fewer or more couplers
30 could be
utilized depending upon the overall size, arrangement, or loading of each of
the storage racks
12.
[0025] Referring now to Figs. 2a and 2b, the individual coupler 30 is
shown connected
between the pair of spaced uprights 18a and 18b. The coupler 30 generally
includes a
coupling bracket 34 and a receiving bracket 36 mounted to upright 18b and a
movement
bracket 38 mounted to the opposite upright 18a. The details of each of the
components of the
coupler 30 will be described in greater detail below.
[0026] Referring now to Fig. 2b, the movement bracket 38 includes a
mounting flange
40 and a movement plate 42 integrally joined to each other along a corner 44.
The mounting
flange 40 includes a series of mounting holes 46 that each receive a connector
to hold the
movement bracket 38 on one of the uprights.
[0027] The movement bracket 38 includes a pair of movement slots 48
formed in the
movement plate 42. As illustrated in Fig. 7b, each of the movement slots 48
extends from a
first end 50 to a second end 52 to define the range of movement for the
coupler.
[0028] Referring back to Fig. 2a and 2b, the coupling bracket 34 includes
a pair of
coupling tabs 54 that each extend at a 90 angle relative to the coupling
plate 56. The
coupling plate 56 in turn is connected to a flange 58 having a series of
mounting holes 60 that
allow the coupling bracket 34 to be mounted to one of the uprights 18b.
[0029] As best seen in Fig. 6a, each of the coupling tabs 54-extends at a
90 angle
relative to the coupling plate 56 and terminates at an end 62. In the
embodiment shown in
Figs. 6a-6c, the coupling bracket 34 is formed from a single piece of metallic
material bent to
the shape and configuration shown.
[0030] As illustrated in Figs. 2a and 2b, the width of the coupling tab
54 is less than
the width of the open slot 48 formed in the movement bracket 38. Thus, when
the coupler 30
is assembled as shown in Figs. 2a and 2b, each of the coupling tabs 54 extends
through one of
the open slots 48 and is movable along the length of the open slot 48.
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[0031] Referring back to Figs. 2a and 2b, the coupler further
includes the receiving
bracket 36 mounted to the same upright 18b as the coupling bracket 34. The
receiving
bracket 36 includes a plate 64 connected to a mounting flange 66 along the
corner 68. The
mounting flange 66 includes a series of mounting holes 70. When the mounting
flange 58 of
the coupling bracket is positioned adjacent to the mounting flange 66 of the
receiving bracket
36, the mounting holes of each component are aligned with each other as shown
in Fig. 2b
such that common connectors can be used to secure the components to the
upright 18b.
[0032] Referring now to Fig. 8b, the plate 64 includes a pair of
receiving slots 72.
Each of the receiving slots 72 has a width approximately equal to the width of
the slots 48
formed in the movement plate 42 (Fig. 7b). The width of the receiving slots 72
is slightly
greater than the width of the coupling tabs 54 formed as part of the coupling
bracket 34 (Fig.
6a).
[0033] In the embodiment of the disclosure shown in Figs. 2a and 2b,
the coupling
bracket 34, the receiving bracket 36 and the movement bracket 38 are each
formed from a
plate of steel having a uniform thickness and bent and stamped to the desired
configuration
shown.
[0034] Fig. 3 illustrates the coupler 30 of the present disclosure
assembled and
mounted between a pair of the uprights 18a and 18b. As illustrated, both the
coupling bracket
34 and the receiving bracket 36 are mounted to the same upright 18b while the
movement
bracket 38 is mounted to the opposite upright 18a. As illustrated, the
coupling tabs 54 of the
coupling bracket 34 extend through the movement slots 48 formed in the
movement bracket
38. The end 62 of each coupling tab 54 extends through one of the receiving
slots 72 formed
as part of the receiving bracket 36. The end 62 of the coupling tabs 54 is
held in this position
by a removable connector 74.
[0035] The configuration of the removable connector 74 is best shown
in Figs. 4 and
5. As illustrated in Fig. 4, the removable connector 74 extends through the
coupling tab 54.
In the embodiment shown in Fig. 5, the removable connector 74 is a bolt having
a head 76
and a shaft 78. The shaft 78 includes a hole 80 that receives a retainer 82.
The retainer 82
includes a bent latch portion 84 that receives the generally straight locking
portion 86. As
illustrated in Fig. 5, the retainer 82 can be removed by flexing the straight
locking portion 86
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against the coil spring portion 85 and out of the latch portion 84 and
removing the straight
locking portion 86 from the hole 80. Although the one specific configuration
for the retainer
82 is shown in Fig. 5, it should be understood that the retainer 82 could be
replaced by other
types of mounting arrangements.
[0036] Referring back to Fig. 4, when the coupling tab 54 is retained as
illustrated, the
removable connector 74 prevents separation of the coupler while allowing the
coupling tab 54
to move in either direction within the open slots 48, as illustrated by arrows
88. In addition to
the movement in the direction shown by arrows 88 in Fig. 4, the components of
the coupler 30
can also move in the vertical direction, as shown by arrows 89 also in Fig. 4.
The movement
in the vertical direction shown by arrows 89 is possible due to the size
difference between the
coupling tab 54 and the open slots 48. Further, the coupling tab 54 is able to
move in a third,
orthogonal direction due to the slight spacing between the removable connector
74 and a face
surface 90 of the receiving bracket 36, as shown in Figs. 3 and 5. As
illustrated in Fig. 3, an
open space 92 is formed between the coupling bracket 34 and the receiving
bracket 36. The
open space 92 further allows for movement between the movement bracket 38 and
the
coupling bracket 34 and the receiving bracket 36 in the assembled condition
shown in Fig. 3.
The open space 92 is created by the bent configuration of the coupling tab 54.
[0037] The movement of the coupling tabs 54 within the slots 48 allows the
distance
between the pair of uprights 18 to vary, such as during movement of the unit
over an uneven
floor. The use of the couplers shown in Fig. 1 allows for the required
structural strength to
allow the combined units to be evaluated as a single unit while still allowing
the required
flexibility of movement between the two storage racks.
100381 This written description uses examples to disclose the invention,
including the
best mode, and also to enable any person skilled in the art to make and use
the invention. The
patentable scope of the invention is defined by the claims, and may include
other examples
that occur to those skilled in the art. Such other examples are intended to be
within the scope
of the claims if they have structural elements that do not differ from the
literal language of the
claims, or if they include equivalent structural elements with insubstantial
differences from
the literal languages of the claims.
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