Storage rack reinforcement/repair unit

Abstract

A method and apparatus for the repair, reinforcement and protection of damaged upright support members of typical commercial and industrial storage rack systems is disclosed. The invention employs a rigid vertical channel attached to an accommodating base plate to wrap around and bring into secure alignment a damaged upright storage rack support member. The invention is designed to be used to repair damaged upright storage rack support members without requiring the disassembly of the storage rack or the removal of product being stored on the rack.

Description

FIELD OF THE INVENTION

This invention relates generally to commercial and industrial storage rack systems. More particularly, the present invention relates to a new and improved method and apparatus for repairing, reinforcing and protecting damaged upright support members of typical commercial and industrial storage rack assemblies in use today.

BACKGROUND OF THE INVENTION

Forklift and other mechanical damage to the upright support members or legs of commercial and industrial warehouse-type storage racks is a major problem in the United States and in other industrialized countries. The support legs and other frame members of most commercial and industrial grade storage rack systems in use today are formed or constructed utilizing 14 to 16-gauge sheet steel. The sheet steel used to form these legs or frame members is usually cold rolled into a square shape thereby forming a structural frame member having four corners. The corners of the structural member formed in this manner give the member its strength. However, once a structural member is damaged and one or more corners of the member become bent, twisted, broken or cut, the compression strength of the member, especially members used for upright support, is severely compromised. In most cases the damaged support member cannot be effectively repaired and the member (or quite often the entire rack assembly) must be completely replaced. While the storage rack systems in use today are indeed strong and durable, the structural frame members, especially the legs or ground support members, are easily damaged by the heavy equipment typically used to load and unload product from the shelves or decking of the storage racks. The replacement or repair of damaged upright ground support members of these storage rack systems is, at best, a very labor intensive, and thus very costly, operation resulting in tens of thousands of dollars in material and repair costs every year. Presently, in order to repair or replace a damaged upright support member of a typical warehouse-type storage rack, the product being stored on the rack must first be removed from the rack shelves or decking and then stored or reshelved at another location. The rack decking and the rack beams must then be removed from the storage rack assembly for access to the damaged rack support member. Once the damaged rack support member has been repaired, or in most instances—replaced, the rack decking and the rack beams must be reassembled and the previously relocated product must then be retrieved and returned to the rack decking and placed in the proper order for inventory purposes.

It would be expedient; therefore, to provide a method and apparatus for efficiently repairing, reinforcing and protecting damaged upright support members of typical commercial and industrial storage rack assemblies wherein said assemblies do not have to be disassembled and wherein existing product being stored on said storage racks does not have to be removed and relocated in order to effectuate the repair operation.

Various devices have been proposed for protecting, replacing or repairing the frame members of warehouse-type storage racks. However, known devices, such as those disclosed in applicant's information disclosure statement submitted herewith, are not without disadvantages, disabilities, limitations and/or shortcomings which are addressed and overcome by the design, function and use of the present invention.

The present invention is a modification and significant improvement over prior art and incorporates unique, novel and cost effective design features which distinguish the invention over the existing art.

SUMMARY OF THE INVENTION

In view of the foregoing, it is a primary object of this invention to provide a new and improved method and apparatus for the repair, reinforcement and protection of damaged upright support members of typical storage rack systems.

According to an embodiment of the invention, a storage rack reinforcement and repair unit comprises a C-shaped, hot-cast, structural steel channel attached at one end to an oversized U-shaped base or floor plate. Said channel having a plurality of strategically placed, and precisely spaced, holes along its length for engaging the pre-stamped deck adjustment holes of typical storage rack upright support members. Said U-shaped floor plate and said C-shaped channel having dimensions designed to nestably wrap around the exterior dimensions of typical storage rack upright support members.

An important advantage of the present invention is the provision of a storage rack reinforcement and repair unit which can be effectively used to repair, reinforce and protect damaged upright support members of typical warehouse-type storage rack systems without having to disassemble the storage rack or remove product(s) or other stored items from the shelves or decking of the storage rack in order to effectuate the repair operation.

Another important advantage of the present invention is the provision of a storage rack reinforcement and repair unit that does not require the removal or replacement of damaged upright support members or cross brace members.

Another advantage of the present invention is the provision of a storage rack reinforcement and repair unit that substantially reduces the cost for repairing damaged upright support members.

A further advantage of the present invention resides in the ability to install and use the invention on virtually any damaged upright storage rack support member, regardless of the extent of damage to the support member.

Another advantage of the present invention is the provision of a storage rack reinforcement and repair unit that does not require the cutting of the old or damaged upright support members in order to effectively install and use the invention.

Another advantage of the present invention is the provision of a storage rack reinforcement and repair unit for repairing and reinforcing damaged upright support members that provides much greater protection from future damage to said support members.

Another advantage of the present invention resides in its ability to be retrofitted to any existing upright storage rack support member.

A further advantage of the present invention resides in the ability to use the device to straighten damaged storage rack support members during the installation and repair operation.

A further advantage of the present invention is the provision of a storage rack reinforcement and repair unit that does not require cutting, heating or welding to effectively install and use the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features, and advantages of the present invention will be apparent from the following more particular description of preferred embodiments as illustrated in the accompanying drawings in which reference characters refer to the same parts throughout the various views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.

FIG. 1 is a perspective view of a preferred embodiment of the invention shown fully deployed and attached to an upright support member of a typical storage rack assembly.

FIG. 2 is a perspective view of a damaged upright support member of a typical storage rack assembly.

FIG. 3 is a perspective rear view of the base plate and structural channel of the embodiment of FIG. 1 shown in an uninstalled configuration.

FIG. 4 is a prospective side angle view of the embodiment of FIG. 1 showing the device in a fully deployed and attached configuration.

FIG. 5 is a prospective rear view of the embodiment of FIG. 1 showing the device in a fully deployed and attached configuration.

DETAILED DESCRIPTION OF THE DRAWINGS

In accordance with an embodiment of the invention, FIG. 1 shows a storage rack reinforcement and repair unit 100 designed for use in repairing, reinforcing and protecting damaged upright support members 201 of typical commercial or industrial warehouse-type storage rack assemblies 200.

The storage rack reinforcement and repair unit 100 of FIG. 1 comprises a channel member 10 having a C-shaped cross-section; said channel member 10 being attached at one end to a U-shaped base plate member 20.

As best seen in FIG. 3, the U-shaped base plate member 20 comprises a flat structural steel plate 21 having a top side 22 and a bottom or floor side 23 and having an essentially square-shaped section 24 centrally removed from said plate 21 at one edge 25.

The removal of said square-shaped section 24 from said plate 21 creates the overall U-shape of said plate member 20 and forms an internal recessed edge 26 situated between a pair of internal parallel edges 27. Said base plate member 20 having dimensions extending substantially beyond the external cross-sectional dimensions of said channel member 10. The base plate member 20 further comprises a plurality of mounting holes 28 spacably positioned along the perimeter of said plate 21 for use in attaching or securing said base plate member 20 to the floor of a warehouse building or other structure.

The C-shaped channel member 10, by definition, has three sides comprising a face panel 11 and two side panels 12 and having a top end 13 and a bottom end 14. As best seen in FIGS. 1, 3 & 5, the face panel 11 of said channel member 10 further comprises a plurality of strategically placed, and precisely spaced, attachment holes 15 along the length of said channel member 10. Said attachment holes 15 are designed for aligning with, and for engagement of, the pre-stamped adjustment holes 202 of a rack support member 201 during the installation of the storage rack reinforcement and repair unit 100. As best viewed in FIG. 3, the bottom end 14 of said channel member 10 is rigidly attached, as by welding, to the top side 22 of the steel plate 21 of said U-shaped base plate member 20 along the internal recessed edge 26 and along a portion of the internal parallel edges 27 of said steel plate 21 as shown so as to cause said channel member 10 to extend perpendicularly and vertically from said base plate member 20. The internal cross-sectional dimensions of the channel member 10 are designed to align with the dimensions of the recessed edge 26 and the parallel edges 27 of said steel plate 21 as shown. As best seen in FIGS. 4 & 5, the internal cross-sectional dimensions of the channel member 10 and the dimensions of the square-shaped section 24 of the U-shaped plate member 20 are designed to wrap around and nestably accommodate the external cross-sectional dimensions of said storage rack support member 201.

In order to use the invention to repair, reinforce and protect the damaged support member 201 of a typical storage rack assembly 200, the storage rack reinforcement and repair unit 100 thus formed is first bolted to the floor utilizing the mounting holes 28 of said of said base plate member 20. The unit 100 is bolted to the floor at the precise location occupied by, or previously occupied by, said damaged storage rack support member 201. Once the unit 100 has been firmly bolted to the floor, the channel member 10 of said unit 100 is then used to leverage the damaged support member 201 into alignment with said channel member 10 and thereby cause said support member 201 to nestably engage the side panels 12 and face panel 11 of said channel member 10. Once the damaged support member 201 is properly aligned with, and engaged by, the channel member 10 and base plate member 20 of said unit 100, the support member 201 is then bolted to said channel member 10 utilizing the attachment holes 15 situated along the face panel 11 of said channel member 10.

While the invention has been particularly shown and described with reference to the preferred embodiment thereof, it will be understood by those skilled in the art that various alterations in form, detail and construction may be made therein without departing from the spirit and scope of the invention.

Claims

1. A storage rack repair and reinforcement unit for repairing, reinforcing and protecting a damaged upright support member of a storage rack assembly comprises:

an elongated channel member having a C-shaped cross-section defining a face panel and two side panels and having a plurality of alignment and attachment holes spaceably positioned along the length of the face panel of said channel member; and,

a base plate member perpendicularly attached to one end of said channel member, said base plate member having dimensions extending substantially beyond the external cross-sectional dimensions of said channel member and said base plate member having a portion of said base plate removed along one of its sides so as to align with the internal cross-sectional dimensions of said channel member;

means for securing said base plate member to a rigid flat surface such as a concrete or metal floor; and,

means for securing said upright support member of said storage rack assembly to the face panel of said channel member.

2. The apparatus of claim 1, wherein the internal cross-sectional dimensions of said channel member are sufficient to accommodate and nestably receive the external linear dimensions of said upright support member.

3. The apparatus of claim 1, wherein said elongated channel member comprises a length of structural steel.

4. The apparatus of claim 1, wherein said base plate member is U-shaped and is comprised of structural steel.

5. The apparatus of claim 1, wherein said base plate member is rigidly attached to said elongated channel member as by welding.

6. The apparatus of claim 1, wherein said base plate member is secured to said rigid flat surface by a plurality of bolts which engage mounting holes spacably positioned around the perimeter of said base plate member.

7. The apparatus of claim 1, wherein said upright support member is secured to the face panel of said channel member by a plurality of bolts which engage said alignment and attachment holes of said face panel.

8. The apparatus of claim 1, wherein said storage rack repair and reinforcement unit is used to leverage said damaged upright support member into proper alignment for attachment to the face panel of said channel member.

9. A method of repairing, reinforcing and protecting a damaged upright support member of a storage rack assembly comprising the steps of:

securing a storage rack repair and reinforcement unit to the floor or other surface supporting said storage rack assembly at the location on said supporting surface occupied by, or previously occupied by, said damaged upright support member; said storage rack repair and reinforcement unit comprising an elongated channel member vertically attached to a base plate member,

using said storage rack repair and reinforcement unit as leverage to bend or otherwise straighten said damaged upright support member so as to align said support member with the elongated channel member of said repair and reinforcement unit, and,

attaching said upright support member to said elongated channel member.

10. The method of claim 9, wherein said channel member has a C-shaped cross-section defining a face panel and two side panels and having a plurality of alignment and attachment holes spaceably positioned along the length of said face panel of said channel member.

11. The method of claim 9, wherein said base plate member is rigidly attached to one end of said elongated channel member and has dimensions extending substantially beyond the external cross-sectional dimensions of said channel member and having a portion of said base plate member removed along one of its sides so as to align with the internal cross-sectional dimensions of said channel member.

12. The method of claim 9, wherein said elongated channel member comprises a length of structural steel.

13. The method of claim 9, wherein said base plate member is U-shaped and is comprised of structural steel.

14. The method of claim 9, wherein said base plate member and is rigidly attached to said elongated channel member as by welding.

15. The method of claim 9, wherein said base plate member is secured to said supporting surface by a plurality of bolts which engage mounting holes spacably positioned around the perimeter of said base plate member.

16. The method of claim 10, wherein said upright support member is attached to said elongated channel member by a plurality of bolts which engage said alignment and attachment holes of said face panel.