Load support system

Abstract

A load support system or shelf system includes vertical supports and at least two horizontally extending beams attached to the vertical supports. The cross-section of a beam is L-shaped, and the joists extend along and rest upon a relieved horizontal surface of each of the beams. A plurality of spaced-apart cross trusses are affixed to each of the joists to form a unitary, open lattice for supporting loads. The number and spacing of the cross trusses can be adjusted to securely support the load designed to be accommodated by the system, but the number of trusses can be minimized to correspondingly reduce the weight and cost of the system.

Description

FIELD OF THE INVENTION

The present invention relates generally to load support and load storage systems, and more particularly to a rigid, unitary support structure adapted for use in conjunction with a pallet support rack.

BACKGROUND OF THE INVENTION

Various adjustable load support or shelving systems are commercially available. The shelving arrangements in these systems can be permanently or temporarily adjusted to accommodate loads of various sizes and shapes.

For example, U.S. Pat. No. 3,463,325 to Zagotta et al. shows a pallet rack beam retainer that includes individual channel-shaped load-bearing cross members positioned in a spaced, parallel arrangement. The ends of the cross members are seated on a ledge extending along the length of outer rail members and are held in position by a retaining bracket. This document does not disclose a unitary grid structure.

In addition, U.S. Pat. No. 3,814,034 to Seiz shows a load support structure including a set of individual parallel, spaced, load-bearing cross members, the ends of which are placed on ledges that extend along the length of the rails and are secured to a respective ledge with an interlocking flange arrangement. This document also does not disclose a unitary grid member.

The load support systems of the prior art do not include a unitary grid structure that can be formed to minimize the number of system components used and to correspondingly minimize the cost and weight of the system. A removable grid structure formed of inter-connected (preferably, welded) cross members would provide additional support under a pallet stored on a typical warehouse pallet rack system.

It is desired to provide a load bearing system that can be customized not only in its spatial configuration but also in the number, size and shape of the various components.

It is also desired to provide a system that securely supports a load of predetermined size, shape and weight with a minimum number of system parts at minimum expense and with maximum ease of construction.

SUMMARY OF THE INVENTION

According to the present invention, a removable unitary (preferably, welded) grid structure includes a plurality of cross members or trusses joined by side rails or joists to support a pallet or other load. The grid structure is supported along the beams of a pallet rack. In a preferred embodiment, the grid structure includes from four to six parallel, evenly spaced cross trusses that are attached (preferably, by welding) to two joists at their ends in a grid arrangement, although from two to twelve cross trusses can be provided.

More specifically, the load support system according to the present invention comprises, in combination, at least two horizontally extending beams for attachment to vertical support means, the beams having confronting, continuous L-shaped cross sections, and a load support module, the module comprising at least two joists each adapted to extend along and rest upon a relieved horizontal surface of one of the L-shaped beams; and a plurality of spaced-apart cross trusses, each truss being affixed to each of the joists to form a unitary, open lattice for supporting loads. The number of cross trusses forming the lattice and the spacing between the cross trusses are selected in accordance with the load which the system will support. It is preferred that the joists are shorter than the beams upon which they rest. An adjustable attachment means is included for attaching the beams to the vertical support means in any one of a range of vertically spaced apart positions.

In a preferred embodiment, at least some of the cross trusses have an inverted U-shaped cross-section. The cross truss inverted U-shaped cross-section can include a depressed intermediate strengthening section. The intermediate strengthening section includes opposed downwardly extending arms away from a bight and an interconnected web portion affixed to and extending between the strengthening section arms.

The load support system of the present invention includes a unitary grid structure that can be formed to minimize the number of system components used and to correspondingly minimize the cost and weight of the system. In particular, a removable grid structure formed of welded cross members provides additional support under a pallet stored on a typical conventional pallet rack system. The grid structure can be positioned and removed from the load support system as a single unit.

The load bearing system described and claimed herein can be customized not only in its spatial configuration but also in the number, size and shape of the various components. The system securely supports a load of predetermined size, shape and weight with a minimum number of parts at minimum expense and with maximum ease of construction.

Other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which comprise a portion of the present disclosure:

FIG. 1 is an isometric view of a horizontal support or shelf module made in accordance with the invention;

FIG. 2 is an isometric view of the system including the horizontal support module, associated support beams and supporting columns;

FIG. 3 is a top plan view of the support module or shelf member shown in FIG. 1;

FIG. 4 is an end elevational view of the support module or shelf member shown in FIG. 3;

FIG. 5 is a side elevational view of the support module or shelf member shown in FIG. 3;

FIG. 6 is a fragmentary sectional view taken substantially in the plane of line 6-6 in FIG. 3; and

FIG. 7 is a fragmentary sectional view taken substantially in the plane of line 7-7 in FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

While the invention will be described in connection with a preferred embodiment, it should be understood that there is no intention to limit the invention to the particular embodiment shown and described. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the accompanying claims.

The present invention relates to a unitary load-bearing grid structure removably supportable along the beams of a conventional pallet rack. In a preferred embodiment, the grid structure includes a plurality of cross members joined at their respective ends (for example, by welding) to a pair of side rails which removably engage horizontal support beams of a conventional pallet rack structure. The cross members can comprise five parallel, evenly spaced bars connected at their respective ends to a pair of spaced-apart side rails. The grid structure provides additional support for materials stored on a typical warehouse pallet rack system.

FIGS. 1-5 show a load support system 10 comprising front and rear vertical supports 12, at least two horizontally extending beams 14 for attachment between the front vertical supports and the rear vertical supports, respectively, and conventional side braces (not shown). The location of the beams 14 on the front and rear supports 12 can be determined in a conventional manner at any of a range of vertically separated positions by a corresponding range of apertures 16 and corresponding inter-engaging pins, tabs, hooks or end plates (not shown).

In accordance with the invention, a rigid, unitary support structure comprising a support or shelf module 18 includes at least two substantially parallel side support joist members 20 and a plurality of spaced apart, substantially parallel pallet support bars or cross trusses 22 affixed to each of the joists 20 to form a unitary, open lattice 18 for supporting loads. The shelf module provides for ease of set-up and storage, more uniform spacing of the cross trusses 22 and thus more uniform support of the load. A plurality of cross trusses 22 can be provided—for example, from two to twelve trusses with four to six trusses being more preferred, and five trusses being most preferred, depending on the required load capacity. Most importantly, the shelf module 18 can be positioned and removed from the support structure as a single unit.

As shown in FIG. 6, each horizontally extending beam 14 preferably defines an L-shape in cross section, and each joist member 20 is adapted to extend along and rest upon a relieved horizontal surface 24 of one of the beams 14. It is an advantage of the invention that this open lattice 18 need not necessarily be affixed directly to the horizontal beams 14. The shelf module 18 is preferably dimensioned so that the module essentially snap-fits into the space between the beams 14. Thus, one shelf module can be substituted for another based on the use requirements.

As suggested in FIG. 6, the joist members 20 can be square U-shaped channels formed of any appropriate steel, other metal or other material. As shown in FIG. 7, the cross trusses 22 preferably have an inverted U-shaped cross-section. To further strengthen these trusses, the cross truss inverted U-shaped cross-sections can each include a depressed intermediate strengthening section 28. This intermediate strengthening section 28 includes opposed portions 30 extending away from a longitudinally extending channel 32 and an intermediate connector web portion 34 affixed to and extending between strengthening sections 36. The width and depth of a cross truss can be increased or decreased based on the required load bearing capacity.

In accordance with one of the advantages of the present invention, the number of cross trusses 22 are selected, and the spacing of those trusses 22 with respect to one another are provided, in accordance with predetermined design criteria based upon the size, shape, load and other known factors characterizing the load to be supported by the system. By minimizing the number of cross trusses 22 utilized, the amount of material and consequent material expense involved in creating the load system can be minimized. Depending on the load requirements, one shelf module 18 with more or less cross trusses can be substituted for another shelf module.

It will also be noted from FIG. 2 that the joist members 20 can be shorter than the beams 14 upon which the joist members 20 rest. This permits the modular load supporting lattice 18 to be shifted horizontally so as to be placed most effectively; and also to minimize the amount of steel or other material involved in the manufacture of the system.

In addition, the various components can be formed of galvanized steel or any other suitable material and can include a powder coat finish as may be required for the particular use.

The foregoing description and drawings of the present invention are illustrative and are presented by way of example. As will be appreciated by those skilled in the art of shelving design and manufacture, various modifications can be made in the configuration and construction of the invention without departing from the spirit and scope thereof.

Claims

1. A load support system comprising, in combination:

at least two horizontally extending beams for attachment to vertical support means, the beams having confronting, continuous L-shaped cross sections; and

a load support module comprising at least two joists, each joist adapted to extend along and rest upon a relieved horizontal surface of one of the L-shaped beams, and a plurality of spaced-apart cross trusses, each truss being affixed to each of the joists to form a unitary, open lattice for supporting loads.

2. The load support system according to claim 1 wherein the number of cross trusses forming the lattice and the spacing between the cross trusses are selected in accordance with the load which the system will support.

3. The load support system according to claim 1 including from two to twelve substantially evenly spaced cross trusses.

4. The load support system according to claim 1 including from four to six substantially evenly spaced cross trusses.

5. The load support system according to claim 1 wherein at least some of the cross trusses have an inverted U-shaped cross-section.

6. The load support system according to claim 5 wherein the cross truss inverted U-shaped cross-section includes a depressed intermediate strengthening section.

7. The load support system according to claim 6 wherein said intermediate strengthening section includes opposed downwardly extending arms away from a bight and an interconnected web portion affixed to and extending between the strengthening section arms.

8. The load support system according to claim 1 wherein said the joists are shorter than the beams upon which they rest.

9. The load support system according to claim 1 further including an adjustable attachment means for attaching the beams to the vertical support means in any one of a range of vertically spaced apart positions.

10. A rigid, unitary support structure adapted for use in conjunction with a pallet support rack comprising:

a) at least two substantially parallel side support joist members; and

b) a plurality of substantially parallel cross trusses immovably connected at opposed ends thereof to at least one of the side support joist members whereby the support structure, when mounted on the support rack, is capable of supporting a load and is removable from a load support system as a single unit.

11. The rigid, unitary support structure according to claim 10 wherein the number of cross trusses and the spacing between the cross trusses are selected in accordance with the weight of the load that the pallet support rack will support.

12. The rigid, unitary support structure according to claim 10 including from two to twelve substantially evenly spaced cross trusses.

13. The rigid, unitary support structure according to claim 10 including from four to six substantially evenly spaced cross trusses.

14. The rigid, unitary support structure according to claim 10 wherein at least some of the cross trusses have an inverted U-shaped cross section.

15. The load support system according to claim 14 wherein the cross truss inverted U-shaped cross-section includes a depressed intermediate strengthening section.

16. The load support system according to claim 15 wherein said intermediate strengthening section includes opposed downwardly extending arms away from a bight and an interconnected web portion affixed to and extending between the strengthening section arms.

17. The load support system according to claim 10 wherein said the joists are shorter than the beams upon which they rest.

18. The load support system according to claim 10 further including an adjustable attachment means for attaching the beams to the vertical support means in any one of a range of vertically spaced apart positions.