Pallet racks

Abstract

This invention provides a pallet rack that can stably and efficiently store long pallets that exceed the dimensions of standard pallets. [Solution] The pallet rack has a rectangular frame on its upper surface 1 and is a rectangular parallelepiped shape that can be connected and stacked horizontally and vertically. In this pallet rack, the pallet placement area formed on the upper surface is formed with a width of at least twice the width of the pallet in the left-right direction. The upper surface is composed of a frame consisting of a front frame 11a at the front, a rear frame 11b at the rear, and side frames 12a and 12b on both sides.

Description

Technical Field

[0001] The present invention relates to logistics and material handling equipment technology, and particularly to a pallet rack capable of placing long pallets.

Background Art

[0002] In the storage of goods in warehouses and factories, pallets and pallet racks are widely used.

[0003] The pallet rack, also called a nesting box (nestener), is mainly designed to fit 11-type pallets (about 1100 mm × 1100 mm) and 14-type pallets (about 1400 mm × 1100 mm), and efficiently stores the goods loaded on these pallets in multiple tiers.

[0004] In recent years, the number of long parts such as semiconductor-related components has been increasing, and many of these parts are long objects with lengths (for example, about 1.1 m to 3.5 m) that greatly exceed the dimensions of conventional pallets.

[0005] Such long objects cannot be properly accommodated in conventional pallets and pallet racks, and are handled in a state where they protrude greatly from the pallets. Therefore, as conventional storage methods, methods such as directly placing long pallets flat on the floor surface or arranging and supporting a plurality of pallets side by side are adopted.

[0006] [[ID=2)7]] However, storage by flat placement can only arrange goods in one layer, so the limited space in the warehouse cannot be effectively utilized, and the storage efficiency is significantly reduced. Also, in the case of support using a plurality of pallets, there is a lack of stability, the risk of load collapse and tipping is high, and it is difficult to ensure safety.

[0007] Furthermore, long pallets tend to have an uneven weight distribution and a high center of gravity. As a result, even when stored in a pallet rack, the stacked state becomes unstable, making them prone to tipping over or falling due to external forces, vibrations, or impacts from forklift operations.

[0008] Furthermore, when transporting long pallets, conventional forklifts do not provide sufficient support, making stable transport difficult. This forced workers to resort to inefficient operations, such as transporting pallets in multiple trips.

[0009] Furthermore, when storing long items on pallet racks, a wide aisle width is required for the vehicle to rotate and adjust its position, which limits the flexibility of the warehouse layout.

[0010] In addition, conventional methods for connecting pallet racks often rely on simple methods using packaging bands (such as PP bands), making it difficult to ensure sufficient strength and durability. Furthermore, the overall stability of the structure may be compromised in the event of external disturbances such as earthquakes or vibrations.

[0011] For example, a conventional pallet rack is a nesting rack in which multiple shelf frames spaced apart in the vertical direction are supported by front, rear and left and right support columns that extend in the vertical direction, and items to be stored are placed on each shelf frame, and each shelf frame consists of a pair of left and right side arms spaced apart in the left and right direction and extending in the front and rear direction, and a rear beam that extends in the left and right direction and is installed between the rear ends of both side arms, connecting the two rear ends, and in each shelf frame, the upper surfaces of both side arms and the upper surface of the rear beam are continuous in the same horizontal plane as the mounting surface on which items to be stored are placed (see, for example, Patent Document 1). [Prior art documents] [Patent Documents]

[0012] [Patent Document 1] Japanese Patent Publication No. 2022-185772 [Overview of the project] [Problems that the invention aims to solve]

[0013] However, conventional pallet racks, such as the one described in Patent Document 1 above, attempt to stably load goods using a multi-tiered shelf structure, but these are based on the assumption that the stored items will fit within the dimensions of the pallet, and long items that significantly exceed the dimensions of the pallet cannot be loaded onto them.

[0014] Thus, conventional technology lacks a satisfactory solution for the storage and transportation of long pallets in terms of storage efficiency, safety, workability, and transportation efficiency.

[0015] The present invention aims to solve the above problems by providing a pallet rack that can stably and efficiently store long pallets that exceed the dimensions of normal pallets. [Means for solving the problem]

[0016] As a result of diligent research, the inventors of this invention have discovered a novel pallet rack with a structure that can accommodate long objects that significantly exceed the dimensions of the pallet, and have completed this invention.

[0017] Thus, the pallet rack according to the present invention is a rectangular parallelepiped shape having a rectangular frame on its upper surface, and is a pallet rack that can be connected and stacked horizontally and vertically, wherein the pallet placement area formed on the upper surface is formed with a width of at least twice the width of the pallet in the left-right direction.

[0018] Thus, in a pallet rack consisting of a rectangular parallelepiped shape with a rectangular frame on its top surface, which can be connected and stacked horizontally and vertically, the pallet placement area formed on the top surface is formed with a width of more than twice the width of the pallet in the horizontal direction. As a result, a wider clearance is created in the horizontal direction than in conventional designs, reducing the installation area and saving space. Long pallets can be placed as they are, and a higher storage capacity can be achieved more efficiently. Furthermore, stacking and connecting the racks maximizes the storage capacity of the entire warehouse.

[0019] Furthermore, the pallet rack according to the present invention may be disposed at the bottom of the rectangular parallelepiped shape as needed, and consists of a U-shaped frame with an open front, and has a lower surface that is wider in the left-right direction than the upper surface.

[0020] Thus, the frame is positioned at the bottom of the rectangular parallelepiped and consists of a U-shaped frame with an open front. Since it has a lower surface that is wider in the left-right direction than the upper surface, the wider lower surface of the upper pallet rack overlaps the upper surface of the lower pallet rack. This makes it easier to align the pallets even if there is some misalignment during stacking, resulting in smooth stacking. Furthermore, the U-shaped design of the underside allows for smoother entry of forklifts from the outside, enabling them to reach deeper into the pallet rack and place pallets in precise positions.

[0021] Furthermore, in the pallet rack according to this invention, the rear frame bodies of the upper and lower sections overlap in a plan view as needed. In this way, the rear frame bodies of the upper and lower sections overlap in a plan view, so that the rear frame bodies of the upper and lower structures are aligned at the rear position, the load of the placed pallet is more easily transmitted directly along the downward direction of the support column, and by stabilizing the load transmission, deflection and twisting can be reduced and deformation can be suppressed even when loading long pallets. In addition, the load of the upper pallet rack directly rests on the strong position (rear pillar) of the lower pallet rack, which can reduce the risk of tipping during stacking.

[0022] Moreover, in the pallet rack according to the present invention, if necessary, the front pillar is disposed at the front end of the lower surface portion, and the rear pillar is disposed at both left and right rear ends of the upper surface portion.

[0023] Thus, since the front pillar is disposed at the front end of the lower surface portion and the rear pillar is disposed at both left and right rear ends of the upper surface portion, the column arrangement has an asymmetrical structure in the front and rear, where it is widely supported by the lower surface portion in the front and held at both ends of the upper surface portion in the rear. This enables stability with a wide grounding in the front and firmly supports the load on the upper side in the rear, making it possible to stabilize even long objects whose center of gravity tends to be in the rear and at a high position. In addition, since the interval between the front pillars is wider than that in the rear, it becomes easier to load and unload goods with a forklift. In particular, it is easy to insert and horizontally slide in long objects, and the workability can be improved by maximizing the front opening property.

[0024] Furthermore, in the pallet rack according to the present invention, if necessary, the upper surface portion includes a planar upper surface standing portion that extends upward from the outer end surface in the rear, and a protruding portion that extends protrudingly from the upper end of the front pillar. The lower surface portion includes a housing portion that is formed in a hole shape below the front end portion and can accommodate the protruding portion. When the pallet racks are stacked, the lower surface portion disposed on the upper side is fixed to the upper surface standing portion disposed on the lower side in the rear, and the housing portion disposed on the upper side accommodates and fixes the protruding portion disposed on the lower side.

[0025] Thus, the upper surface portion includes a planar upper surface standing portion that extends upward from the rear outer end surface, and a protruding portion that extends protrudingly from the upper end of the front support column. The lower surface portion includes a housing portion that is formed in a hole shape below the front end portion and can house the protruding portion. When pallet racks are stacked and arranged, the lower surface portion arranged on the upper side is fixed to the upper surface standing portion arranged on the lower side at the rear, and the housing portion arranged on the upper side houses and fixes the protruding portion arranged on the lower side. Therefore, when placing the upper rack, it is only necessary to first abut against the rear standing portion, and accurate positioning in the front-rear direction can be quickly achieved, and the stacking operation of the racks can be made quick and easy.

[0026] In particular, when stacking at a high position, even if the front protrusion is difficult to see, the rear standing portion serves as a guide like a wall, so that the installation work can be completed safely and in a short time. Also, by being supported at two points, namely the rear standing portion and the front support column (protruding portion), the occurrence of metal fatigue and distortion at specific locations is suppressed even in a state of being stacked for a long time. This reduces the burden on the support column and can extend the product life.

[0027] In addition, the pallet rack according to the present invention, as required, includes a standing portion that is formed upright and symmetrically arranged on the left and right outer edges in the left-right direction of the lower surface portion, and an engaging portion that is composed of a through hole or a notch formed in the standing portion. When the pallet racks are arranged continuously, in a state where the two standing portions are in surface contact with each other, a fixing jig that can be detachably fitted is used to connect the two engaging portions to each other.

[0028] Thus, the pallet rack is formed in an upright shape and comprises upright portions arranged symmetrically on the left and right outer edges of the lower surface portion, and engaging portions consisting of through holes or notches formed in the upright portions. When pallet racks are arranged in series, the two engaging portions can be connected using a fixing jig that detachably fits while the two upright portions are in surface contact with each other. By fixing the upright portions in surface contact with each other, excessive force is not applied to the connecting portion, resulting in a robust structure that is resistant to deformation even after long-term use. Furthermore, by bringing the symmetrical upright sections into contact with each other, precise alignment becomes possible, allowing multiple racks to be stably arranged at equal intervals.

[0029] Furthermore, the pallet rack according to the present invention is equipped with reflectors positioned on or near the rear support columns, facing inward, as needed. In this way, the reflective plates are positioned on or near the rear support columns, facing inward, so that when a forklift approaches from the outside, the driver can confirm whether they are moving in the correct direction based on the reflected light from the reflectors while still on the forklift. This functions as a guide for placing the pallet in the center, enabling smooth and reliable placement of the pallet on the rack.

[0030] Furthermore, when the forklift's lights shine on the reflector from outside, the very back of the rack illuminates and stands out, allowing the driver to accurately see the position of the back of the rack, which is difficult to grasp with wide pallet racks. This enables the driver to instantly and accurately determine how far to push the pallet or how far to insert the forks. In addition, the visual limit of the depth becomes clear, which helps to prevent the pallet from colliding with the support pillars or walls at the back. [Brief explanation of the drawing]

[0031] [Figure 1] A perspective view of a pallet rack according to the first embodiment of the present invention is shown. [Figure 2] A perspective view of a pallet rack according to the first embodiment of the present invention is shown. [Figure 3] This shows a front view in plan of a pallet rack according to the first embodiment of the present invention. [Figure 4] This diagram illustrates the stacking of pallet racks according to the first embodiment of the present invention. [Figure 5] This diagram illustrates the stacking of pallet racks according to the first embodiment of the present invention. [Figure 6] This diagram illustrates the pallet placement state of a pallet rack according to the first embodiment of the present invention. [Figure 7] A perspective view of a pallet rack according to a second embodiment of the present invention is shown. [Figure 8] This diagram illustrates the upright portion of a pallet rack according to a second embodiment of the present invention. [Figure 9] This diagram illustrates the state of the upright portion when a pallet rack is connected according to the second embodiment of the present invention. [Figure 10] This diagram illustrates an example of fixing a pallet rack using a fixing jig according to the second embodiment of the present invention. [Figure 11] This diagram illustrates an example of fixing a pallet rack using a fixing jig according to the second embodiment of the present invention. [Figure 12] This diagram illustrates an example of fixing a pallet rack using a fixing jig according to the second embodiment of the present invention. [Figure 13] This diagram illustrates an example of fixing a pallet rack using a fixing jig according to the second embodiment of the present invention. [Figure 14] This diagram shows the configuration of a pallet rack according to a third embodiment of the present invention. [Figure 15] This diagram illustrates the guidance operation of a forklift using a pallet rack according to a third embodiment of the present invention. [Modes for carrying out the invention]

[0032] As shown in Figure 1, the pallet rack according to this embodiment has a rectangular parallelepiped shape with a rectangular frame on its upper surface 1, and is a pallet rack that can be connected and stacked horizontally and vertically, wherein the pallet placement area formed on the upper surface 1 is formed with a width L in the left-right direction that is at least twice the width of the pallet.

[0033] This upper section 1 is composed of a frame consisting of a front frame 11a located at the front, a rear frame 11b located at the rear, and side frames 12a and 12b located on both sides.

[0034] A pallet is a support structure used to place goods, allowing them to be lifted and transported by material handling machinery such as forklifts. It is a plate-like or frame-like structure with a fork insertion space formed on its underside.

[0035] The pallet rack according to this embodiment is also called a nesting box (nestainer), and when not in use, multiple pallet racks can be stacked inside each other to save space for storage. It is mainly used in warehouses, factories, logistics centers, etc., and can accommodate long items (for example, long members of about 1.1m to 3.5m) that do not fit into conventional pallet standards (for example, type 11 or type 14 pallets).

[0036] This allows for the efficient storage and transport of items placed on pallets, especially long items that exceed the dimensions of the pallet.

[0037] By using a forklift to transport this pallet rack, stacked storage and bulk transport become possible. In particular, when storing and transporting long items, it is preferable to use the four-fork type forklift (four-fork forklift) first invented by the present inventor, in order to stably lift materials equivalent to more than two conventional pallets at once.

[0038] This four-legged forklift has been around for a while and is capable of transporting two 1.1m x 1.1m pallets simultaneously, but it has never been used for the kind of three-dimensional storage of long items that we are seeing here.

[0039] Furthermore, because four-forklifts have a wider fork spacing than conventional forklifts, the load on long objects is distributed more evenly, eliminating the cantilevered position of long objects. This prevents cargo collapse, reduces the risk of forklift tipping, and ensures worker safety, thus improving overall work safety.

[0040] Furthermore, using a four-forklift enables the stable transport of long objects. Conventional two-forklifts have difficulty stably lifting long objects equivalent to two pallets. In contrast, with a four-forklift, the support points are distributed across the four forks, increasing the number of pivot points and stabilizing the center of gravity. This suppresses deflection and uneven loading even with loads that have an uneven center of gravity, making it easier to adjust the load balance and enabling stable transport. This reduces the risk of dropping and tipping, as well as damage during transport, allowing for the maintenance of high-quality product quality, such as that of precision parts like semiconductor components.

[0041] Because four-legged forklifts make it easier to adjust the load balance, the delicate balancing required in conventional two-legged forklifts is no longer necessary during operation. This reduces the reliance on operator skill, making them easier for anyone to use and reducing operator stress.

[0042] Furthermore, since a four-legged forklift can always handle long objects with the same grip (four-point support), when used in conjunction with the pallet rack according to this embodiment, the gripping, transporting, and placement methods can be standardized. This enables the realization of dedicated operation for long parts, which was not possible with conventional methods.

[0043] In this case, standardization can be achieved so that anyone can perform the same task even with long items, and the simplification of the operation makes it easier to automate the work. As a result, a new handling method specifically for long items can be established, and logistics equipment can be standardized.

[0044] The long objects targeted by this embodiment are special objects that do not conform to conventional standards, but as described above, they can be easily handled by using a four-legged forklift.

[0045] The pallet rack according to this embodiment has the advantage of being able to be stacked (top and bottom stacked) on a truck, thus doubling the load capacity compared to conventional racks. However, since the placement of long objects is unstable, there were difficulties in safely placing them on the upper level with conventional two-pronged forklifts.

[0046] In this respect, a four-pronged forklift is suitable for vertical (stacked) operation. Because a four-pronged forklift can suppress the swaying of loads even at high altitudes, it can stably lift long objects and accurately position them even on pallet racks of this embodiment that have a height that allows for 2 to 4 stacks, thus achieving stable stacking and storage with minimal error.

[0047] For these reasons, a four-legged forklift is well-suited to the pallet rack according to this embodiment, which allows for the loading of long objects.

[0048] On the other hand, when attempting to store long items on a pallet rack using a forklift, the required aisle width becomes approximately 1.5 to 2 times wider than usual. For this reason, it is preferable to use a special forklift with a wheel axle that can be switched to a sideways position, allowing the vehicle to slide sideways while traveling and enabling space-saving transportation.

[0049] This system allows for operation while maintaining the same aisle width as before, and forklifts can move freely forward, backward, left, and right without changing direction, making it even easier to handle long items in warehouses with limited space.

[0050] This pallet rack has a rectangular parallelepiped shape overall, and a rectangular frame-like upper surface 1 is provided on its top.

[0051] This upper surface portion 1 is a frame structure formed from, for example, steel material (square pipe, channel material, etc.), and as shown in Figure 2, for example, the interior may be formed in a grid pattern, allowing for stable placement of pallets while also reducing weight.

[0052] This frame functions as a support structure for placing pallets or goods directly on it. Reinforcing bars (horizontal and vertical) may be provided as needed to distribute the load and ensure rigidity. The frame is designed to withstand the impact and load during loading by a forklift.

[0053] The upper surface 1 forms a loading area for placing pallets or articles. This loading area can accommodate both cases: placing pallets directly on the surface and placing long objects directly without a pallet. Furthermore, the surface of the loading area can be appropriately treated with anti-slip processing, cushioning material, scratch prevention materials, etc.

[0054] This mounting area is formed with a width of at least twice the pallet width in the left-right direction. Here, pallet width refers to the shorter side dimension of, for example, an 11-type pallet (approximately 1100 mm) or a 14-type pallet (approximately 1400 mm). In this embodiment, the mounting area is formed to be at least twice this width (e.g., 2200 mm or more).

[0055] This allows long items that previously extended significantly beyond the pallet to be supported at at least two points, enabling stable placement while preventing sagging and falling.

[0056] Furthermore, the wider width allows for the horizontal storage of long items, and the system can be expanded by connecting multiple pallet racks, optimizing warehouse space and improving storage efficiency.

[0057] Furthermore, loading pallet racks onto trucks enables stacking and increased loading capacity (for example, more than double the conventional amount), thereby improving transportation efficiency.

[0058] This pallet rack consists of an upper section 1, a lower section 2 positioned below the rectangular parallelepiped shape, and four support columns 3 (front columns 31c and 31d, rear columns 31a and 31b) connecting the upper section 1 and the lower section 2 to form a rectangular parallelepiped shape, thus forming a rectangular parallelepiped skeletal structure overall. This enables load transfer when stacking vertically and ensures rigidity when connecting horizontally.

[0059] The upper part 1 is defined as the pallet placement area, while the lower part 2 is positioned as the foundation structure for stable support.

[0060] This lower section 2 is formed as the lower frame that constitutes this rectangular parallelepiped shape, and plays a role in improving the ground contact stability, transport stability, and load distribution of the entire pallet rack. In particular, when handling long objects, the load tends to be unevenly distributed and the center of gravity tends to fluctuate, so improving the support stability by the lower structure is important.

[0061] More preferably, as shown in Figure 1, a U-shaped frame is provided at the bottom of this rectangular parallelepiped shape, with an open front, and a lower surface 2 that is wider in the left-right direction than the upper surface 1.

[0062] As shown in Figure 3, the lower section 2 is configured as a frame that exhibits a U-shape in plan view. This frame is composed of a pair of left and right side frames, namely lateral frames 22a and lateral frames 22b, and a rear frame, namely a rear frame 21, which are connected in a U-shape.

[0063] Because of its U-shape, the width dimension of the lower part 2 is set to be larger than the width dimension of the upper part 1. As a result, the width of the lower part 2 in the left-right direction is formed to protrude outward by a predetermined amount compared to the width of the upper part 1, and specifically, it may be widened by several tens to several hundreds of millimeters.

[0064] Since no frame member is provided on the front side of the lower section 2, an open space is formed. This open front allows forklift forks to easily enter the lower section 2 through the front opening, enabling the entire pallet rack to be lifted stably. This facilitates loading and unloading of goods by workers and the sliding in of long items, improving work efficiency. In particular, when handling long items, it is suitable for use with forklifts that support multiple forks (e.g., 3-fork or 4-fork systems).

[0065] Furthermore, since the width of the lower section 2 in the left-right direction is wider than that of the upper section 1, the support base is enlarged, improving the overall resistance of the pallet rack to tipping moments. This is particularly effective in situations such as uneven loading of long objects and a high center of gravity when stacking items vertically. In addition, it becomes possible to support loads from the upper section over a wider area, improving the stability of the stacked state.

[0066] More preferably, as shown in Figure 3, the rear frames 11b and 21 of the upper and lower portions 1 and 2, respectively, overlap in a plan view.

[0067] Thus, since the rear frames 11b and 21 of the upper and lower sections 1 and 2, respectively, overlap in a plan view, the rear frames of the upper and lower structures (rear frames 11b and 21) are aligned at the rear position. This makes it easier for the load of pallets placed on the upper pallet rack to be transmitted downwards through the support columns 3 and directly to the lower pallet rack. This stabilizes load transmission, reduces deflection and twisting, and suppresses deformation even when loading long pallets.

[0068] Normally, when placing long items on a pallet rack, they tend to be unevenly loaded, shifting to one side, towards the rear, or having a shifted center of gravity when stacked, resulting in an unstable load distribution. However, by having the rear support lines coincide vertically, the support points are stabilized, which helps to prevent tipping backward and improves stability.

[0069] More preferably, as shown in Figure 3, the front support columns 31c and 31d are arranged at the front ends of the side frames 22a and 22b of the lower surface 2, and the rear support columns 31a and 31b are arranged at both the left and right ends of the rear frame 11b of the upper surface 1.

[0070] As a result, each support column 3 is positioned with a wider width at the front and a narrower width at the rear, resulting in an offset arrangement between the front and rear, which improves the load balance in the front-to-back direction, enhances resistance to tipping in the front-to-back direction, and improves stability against uneven loading of long objects.

[0071] In particular, because each support column 3 has its front support columns 31c and 31d at the outermost left-right ends of the lower surface 2, which are the front ends of the side frames 22a and 22b, the base into which long pallets can enter is widened, and combined with the structure in which the lower surface 2 is wider than the upper surface 1, it becomes more resistant to tipping moments.

[0072] Because the distance between the front support columns 31c and 31d is wider than that between the rear support columns 31a and 31b, loading and unloading of goods by forklift is made easier, especially for inserting and sliding long items in, and work efficiency is improved by maximizing the front opening.

[0073] Thus, the arrangement of the support columns 3 results in an asymmetrical structure where the lower surface 2 provides broad support at the front, while the upper surface 1 holds the load at both ends at the rear. This provides stability with a wide contact area at the front, and firmly supports the load from above at the rear, allowing for stability even with long objects whose center of gravity tends to be at the rear and high.

[0074] While this pallet rack can be used individually, it is typically used in combination with other units.

[0075] This pallet rack has a structure that allows for stacking multiple levels (e.g., 2 to 4 levels) in the vertical direction. For example, by fitting the legs of the upper pallet rack onto the upper surface 1 of the lower pallet rack, or by providing positioning protrusions and receiving parts, or by using upper and lower connecting jigs as needed, a stable stacked state can be maintained.

[0076] Furthermore, as described above, the lower section 2 consists of a U-shaped frame with an open front, and is wider in the left-right direction than the upper section 1. As a result, the wider lower section 2 of the pallet rack on the upper level overlaps the upper section 1 of the pallet rack on the lower level, making it easier to align even if there is some misalignment during stacking, and enabling smooth stacking.

[0077] More preferably, as shown in Figure 1, the upper surface portion 1 comprises planar upper upright portions 13a and 13b extending upward from the rear outer end surface, and projections 14a and 14b extending projectively from the upper end of the front support column 3, while the lower surface portion 2 comprises housing portions 23a and 23b formed in the shape of holes on the underside of the front end, capable of accommodating the projections 14a and 14b.

[0078] The upper upright portions 13a and 13b are members that rise vertically upward from the rear outer end face of the rear frame 11b of the upper portion 1. They are formed as a plate-like or frame-like planar structure and function as load collapse prevention stoppers to prevent long pallets from sliding backward. They also function as positioning aids by contacting the rear frame 21 of the lower portion 2 of the upper pallet rack that they come into contact with during stacking.

[0079] The materials for the upper upright portions 13a and 13b can be formed from steel plates, plate welded structures, pipes, or square timbers.

[0080] The projections 14a and 14b are formed from pin-shaped, prismatic, cylindrical, or other types of projections that protrude upward or in an upward direction from the upper ends of the front supports 31c and 31d. For example, round pins (cylindrical), prismatic blocks, or tapered guide pins can be used.

[0081] The protrusions 14a and 14b can be formed from steel or stainless steel, but from the viewpoint of structural strength and durability, it is preferable to form them integrally with the support column 3 using the same or equivalent material.

[0082] The housing sections 23a and 23b have an open hole structure and are provided on the underside (back side) of the front end of the lower surface section 2, housing the projections 14a and 14b inside. Their shape is formed as, for example, a circular hole, a square hole, or a tapered guide hole.

[0083] The storage sections 23a and 23b are fixed in their vertical positions by fitting the projections 14a and 14b of the pallet rack located on the lower level into their interiors. As a result, even if there is some misalignment when stacking pallets using a forklift, the projections 14a and 14b act as guides to correct the position, thus providing an automatic position correction function. In addition, the upper pallet rack cannot be removed unless it is lifted upwards, thereby improving safety by preventing it from coming loose.

[0084] As shown in Figure 4, the operation of stacking these pallet racks involves transporting the upper pallet rack towards the rear (direction A) using a forklift above the lower pallet rack and placing it on the top surface 1 of the lower pallet rack.

[0085] As a result, as shown in Figure 5(a), when the rear frame of the upper pallet rack reaches the position of the rear frame of the lower pallet rack in a plan view, the lower surface portion 2 of the upper pallet rack is fixed in contact with the upper upright portions 13a and 13b of the lower pallet rack (fixed positions B1 and B2), as shown in Figure 5(b).

[0086] Furthermore, in front of the pallet rack positioned at the rear, the protrusions 14a and 14b of the lower pallet rack are housed in the housing sections 23a and 23b of the upper pallet rack (fixed positions C1 and C2), and are fixed as shown in Figure 5(c).

[0087] In this way, when placing the upper pallet rack, simply bringing it into contact with the rear upper upright sections 13a and 13b allows for quick and accurate positioning in the front-to-back direction, thus facilitating the rapid and easy stacking of pallet racks.

[0088] In particular, when stacking at a high position, even if the front protrusions 14a and 14b are difficult to see, the rear upright section acts as a wall and guide, allowing the installation work to be completed safely and quickly.

[0089] By being supported at two points—the rear upper upright portions 13a and 13b and the front projections 14a and 14b—metal fatigue and distortion are suppressed in specific areas even when stacked for a long period of time, reducing the load on the support column 3 and extending the product lifespan.

[0090] As shown in Figure 6, the pallet placement area formed by this upper surface 1 has a width L that is more than twice the pallet width L1 in the left-right direction. This creates more space in the left-right direction than conventional designs, reducing the installation area and saving space. Long pallets 100, 101, 102, etc. can be placed directly on top, resulting in more efficient and higher storage capacity. Furthermore, stacking and connecting the pallets maximizes the overall storage capacity of the warehouse.

[0091] (Second embodiment) The pallet rack according to the second embodiment, similar to the first embodiment, comprises the upper surface 1, the lower surface 2, and the support columns 3. Furthermore, as shown in Figure 7, it comprises upright portions 41a, 42a, 43a, and 44a (hereinafter, 41a to 44a) formed in an upright shape and arranged symmetrically on the left and right outer edges of the lower surface 2, and engaging portions 5 consisting of through holes or notches formed in the upright portions 41a to 44a.

[0092] When pallet racks are arranged in a series, the engaging portions 5 of both racks can be connected using a fixing jig that allows them to be detachably fitted together while the upright portions 41a to 44a of both racks are in surface contact with each other.

[0093] The upright sections 41a to 44a can be vertical plate-shaped (rib-shaped) members that rise from the left and right ends of the lower section 2, and are arranged symmetrically on the left and right outer edges of the lower section 2. This allows for positioning (alignment) of adjacent pallet racks, and because a contact surface is formed (surface contact), misalignment during connection can be prevented. Furthermore, the symmetrical arrangement allows for connection from either side, providing high versatility.

[0094] The engaging portion 5 consists of through holes or notches formed in the upright portions 41a to 44a, and serves as an engagement point through which a fixing jig passes. Variations in the shape of the through holes and notches allow for compatibility with a variety of fixing jigs. Furthermore, its detachable structure facilitates disassembly and relocation.

[0095] Preferably, the upright sections 41a to 44a are positioned near the four corners (B1, B2, C1, C2) adjacent to the front support columns 31c and 31d, and the rear support columns 31a and 31b, as shown in Figure 7. The strength of the upright sections 41a to 44a can be improved by utilizing the high rigidity of these support columns 3.

[0096] For example, as shown in Figure 8(a), at position C2 adjacent to the front support column 31d, the upright portion 43a is formed flush with the left-right outer end surface of the side frame 22b, as shown in Figure 8(b). It is also formed flush with the left-right outer end surface of the front support column 31d.

[0097] Furthermore, it is provided with a planar top plate 43b that connects the upper edge of the upright portion 43a to the front support column 31d in the horizontal plane. It is also provided with a planar inner upright plate 43c that faces inward on the side frame 22b and is opposite to the upright portion 43a. The same applies to position C1 adjacent to the front support column 31c.

[0098] Furthermore, as shown in Figure 8(a), for example, at position B2 adjacent to the rear support column 31b, the upright portion 44a is formed flush with the left-right outer end surface of the lateral frame 22b, as shown in Figure 8(c).

[0099] Furthermore, as shown in Figure 8(c), the upper edge of the upright portion 44a is connected to the rear support column 31b in the horizontal plane by a planar top plate 44b. The same applies to position B1 adjacent to the rear support column 31a.

[0100] In this state, the pallet racks are connected as shown in Figure 9(a). In this case, at the connection position C3 at the front, as shown in Figure 9(b), the engaging parts 51 and 53 of the adjacent pallet racks are both located at the outer edge of each rack, so they come into contact with each other and make surface contact.

[0101] Similarly, at the rear connection position B3, as shown in Figure 9(c), the engaging portions 52 and 54 of the adjacent pallet racks are both located at the outer edge of each rack, so they abut against each other and make surface contact.

[0102] As a result, the engaging parts 5 are connected at both the front and rear positions of adjacent pallet racks, forming one through hole in each.

[0103] By using a fixing jig that can be detachably fitted into the through-hole formed by the engaging portion 5, the engaging portions 5 are connected to each other, and adjacent pallet racks are fixed in place.

[0104] While not particularly limited, various connection methods can be used for the fixing fixture, including U-shaped fixtures, spring-loaded connectors, sliding fitting structures, pin-hook structures, and bolt-nut connections.

[0105] For example, as shown in Figure 10(a), the fixing jig 500, which is integrated with the spring 501, can be inserted into the through hole formed by the engaging part 5 and rotated to fix it in place. Also, as shown in Figure 10(b), the fixing jig 500 can be fitted into the L-shaped cutout through hole to connect them. Furthermore, as shown in Figure 10(c), the L-shaped cutout plate 503 can be slid and fitted onto the pin 502 provided as the fixing jig 500 to connect them.

[0106] Furthermore, as shown in Figure 11(a), for example, the components can be connected using a fixing jig 500 formed as a bolt and nut in a through hole formed by the engaging portion 5. Also, as shown in Figure 11(b), for example, a fixing jig 500 formed as an iron rod-shaped member can be passed through the through hole formed by the engaging portion 5, and the rod can be fixed from the left and right directions with rubber material or the like. Furthermore, as shown in Figure 11(c), for example, a fixing jig 500 formed as a rod-shaped member with a projection can be inserted into the through hole formed by the engaging portion 5, and the components can be connected by rotating the rod to engage the protrusions.

[0107] In addition to the configuration in which the fixing jig 500 is inserted into the through hole formed by the engaging portion 5 by bringing the upright portions 41a to 44a of adjacent pallet racks into contact with each other as described above, it is also possible to insert the fixing jig 500 into other locations.

[0108] Furthermore, as shown in Figure 12(a), for example, through holes are provided in the top plates 42b and 44b, and the U-shaped fixing jig 500 can be inserted into these holes and hooked onto the left and right pallet racks to secure it. Since the base of the fixing jig 500 is connected by a spring 501, a constant tension is always applied, ensuring stable strength. In addition, because the fixing jig 500 is integrated with the spring 501, it also helps to prevent the fixing jig 500 from being lost.

[0109] Furthermore, as shown in Figure 12(b), for example, T-shaped through holes are provided in the top plates 42b and 44b, and a U-shaped fixing jig 500 integrated with the spring 501 can be securely fixed by simply inserting it into the through hole and sliding it. The tension of the spring 501 creates a strong connecting force, making it highly resistant to vibrations and shaking, and significantly reducing the risk of the pallet rack collapsing even in the event of a major earthquake.

[0110] Furthermore, as shown in Figure 12(c), for example, rectangular through holes are provided in the top plates 42b and 44b, and a U-shaped fixing jig 500, which is integrated with the spring 501, is inserted into the through hole and rotated to secure it. This allows for a stronger connection, which reduces the risk of the pallet rack collapsing even during tremors caused by disasters.

[0111] Furthermore, as shown in Figure 12(d), for example, rectangular L-shaped notches can be provided in the top plates 42b and 44b, and the fixing jig 500 can be fitted into the notches to connect them.

[0112] Furthermore, as shown in Figure 12(e), for example, notches can be provided in the top plate 42b and the top plate 44b, and the notches can be fitted together and interlocked using a fixing jig 500 which also has notches, thereby ensuring a secure connection.

[0113] Furthermore, as shown in Figure 13(a), for example, a rotating hook fitting 502a provided on a front support column 31d adjacent to the front support column 31c can be engaged with a pin 502 provided on the front support column 31c to connect them. Since the hook fitting 502a is integrated with the front support column 31d, it can be prevented from being lost and can be connected without the need for separate fittings.

[0114] Furthermore, as shown in Figure 13(b), for example, through holes are provided in the rear frame 11b and rear frame 21, which are the rear frames of the upper surface 1 of the stacked lower pallet rack and the lower surface 2 of the upper pallet rack, respectively. A fixing jig 500, which is a rod-shaped member made of iron, can be passed through these through holes, and the rod can be fixed from above and below with rubber material or the like.

[0115] Furthermore, as shown in Figure 13(c), for example, a structure integrating a U-shaped fixing jig 500 and a spring 501 can be used to securely fix the components by simply inserting it into the T-shaped through-holes provided in the rear frame 11b and rear frame 21 and sliding it into place. This provides a strong connection force through the tension of the spring 501.

[0116] Furthermore, as shown in Figure 13(c), for example, it is also possible to slide and connect the I-shaped fixing jig 504 through the hole from the large hole to the small hole.

[0117] In this way, by connecting pallet racks near the support columns 3, which are load-bearing members, the load is rationally transmitted, making it possible to suppress deformation and twisting of the pallet racks. Furthermore, because the connection is made closer to the outside of the pallet racks, the effect of preventing lateral displacement is also enhanced, improving stability during loading and handling.

[0118] Furthermore, since the upright sections 41a to 44a and the engaging section 5 are arranged symmetrically, any pallet racks can be connected to each other without worrying about their orientation. This eliminates confusion for workers regarding orientation, improving on-site work efficiency and simplifying manufacturing and inventory management through design standardization.

[0119] Furthermore, by connecting the upright sections 41a to 44a in a surface contact state, the load and force are distributed across the contact surface, preventing rattling compared to point contact or line contact, improving vibration resistance, and providing stability that prevents shifting even during earthquakes or fork contact.

[0120] In this way, by fixing the upright sections 41a to 44a in surface contact with each other, excessive force is not applied to the connecting parts, resulting in a robust structure that is resistant to deformation even after long-term use. Furthermore, by simply bringing the symmetrical upright sections 41a to 44a into contact with each other, precise alignment becomes possible, making it possible to stably arrange multiple pallet racks at equal intervals.

[0121] (Third embodiment) The pallet rack according to the third embodiment, like the first embodiment, comprises the upper surface 1, the lower surface 2, the front support columns 31c and 31d, and the rear support columns 31a and 31b. Furthermore, as shown in Figure 14, it is configured to include reflectors 6 arranged on or near the rear support columns 31a and 31b, facing inward towards the rectangular parallelepiped shape.

[0122] The reflector 6 can be configured such that a reflective layer that efficiently reflects light is provided on the surface of a plate-shaped member made of, for example, a metal plate, a resin plate, or a composite material. As the reflective layer, an aluminum vapor-deposited layer, a reflective film, a retroreflective material (reflector sheet), or a reflective paint can be used.

[0123] Furthermore, the shape of the reflector 6 is not limited to a rectangular shape, but can be changed as appropriate to a circular, strip-shaped, or elongated shape that follows the shape of the support column 3. Multiple reflectors 6 may be arranged with intervals between them in the vertical or horizontal direction, in which case the position can be confirmed in multiple stages according to the fork height of the forklift 200.

[0124] The reflector 6 is positioned on or near the rear support columns 31a and 31b, and is installed inside the pallet rack at an angle θ. The angle θ can be, for example, 30 to 60 degrees, or 45 degrees.

[0125] The reflector 6 can be attached using methods such as welding, bolting, riveting, or adhesive bonding. Furthermore, making the reflector 6 detachable facilitates replacement and maintenance.

[0126] The reflector 6 may be installed on the upper, middle, or lower part of the rear support columns 31a and 31b, but it is preferable to install it at a position corresponding to the entry height of the forks of the forklift 200. This allows for accurate visual confirmation of the distance relationship between the position of the fork tips and the rear end of the pallet rack.

[0127] As shown in Figure 14, the reflector 6 is used by emitting light from the light-emitting unit 201 of the forklift 200 towards one reflector 61 (light emission direction P1), which is then reflected by reflector 61 and then towards the adjacent reflector 62 (light emission direction P2). This reflected light is then reflected again by the adjacent reflector 62 (light emission direction P3) and returns to the forklift 200.

[0128] When the light reflected from the adjacent reflector 62 (in the emission direction P3) is received by the light receiving unit 202 of the forklift 200, it can be determined that the direction of travel of the forklift 200 is the correct straight direction D relative to the pallet rack. As a result, as shown in Figure 15, the forklift 200 can continue to move toward the pallet rack.

[0129] In contrast, if the light reflected from the adjacent reflector 6 (direction of travel P3) is not received by the light receiving unit 202 of the forklift 200, it can be determined that the direction of travel of the forklift 200 is not the correct straight direction D relative to the pallet rack. Therefore, the direction of travel of the forklift 200 can be adjusted until the light is received by the light receiving unit 202 of the forklift 200.

[0130] In particular, the pallet rack according to this embodiment has a structure that allows it to accommodate long items by having a loading area that is more than twice the width of the pallet. Therefore, it tends to be more difficult to determine the correct direction of travel in the depth direction compared to conventional pallet racks. However, the reflector plate 6 makes it easy to visually determine the correct direction of travel.

[0131] Furthermore, with the reflector 6 configured in this way, the position and boundaries in the depth direction within the pallet rack can be clearly recognized during cargo handling operations by the forklift 200, thus preventing over- or under-insertion of the forks. As a result, collisions with the rear of the pallet rack and damage caused by over-pushing of cargo can be prevented, improving safety. In addition, the time required for position confirmation is reduced, contributing to improved work efficiency.

[0132] This improves the precision of the fork insertion position of the Forklift 200, making it possible to prevent accidents such as contact with pallet racks and cargo collapse. In addition, improved visibility for workers can lead to increased efficiency and safety in cargo handling operations.

[0133] The specific shape, size, material, and mounting position of the reflector 6 can be changed as appropriate, and for example, it can be constructed using a reflective sheet, reflective paint, or retroreflective material.

[0134] As described above, the rear support column 3 or its vicinity is equipped with a rectangular parallelepiped-shaped reflector 6 facing inward. Therefore, with the reflectors 6 facing inward on the left and right rear support columns 31a and 31b, when approaching from the outside with a forklift 200, the driver can confirm whether they are moving in the correct direction based on the reflected light from the reflector 6 while remaining on the forklift. This functions as a guide for centering the pallet, enabling smooth and reliable placement of the pallet on the pallet rack.

[0135] Furthermore, when the lights from the forklift 200 shine on the reflector 6 from the outside, the very back of the pallet rack illuminates and stands out, allowing the driver to accurately confirm the position of the back of the pallet rack, which is difficult to grasp with wide pallet racks. This allows the driver to instantly and accurately determine how far to push the pallet or how far to insert the forks. In addition, the depth limit becomes visually clear, which helps to prevent the pallet from colliding with the rear support column 3 or wall. [Explanation of Symbols]

[0136] 1 Top part 11a Front frame 11b Rear frame 12a Side frame 12b Side frame 13a Top standing section 13b Upper surface standing part 14a Protrusion 14b Protrusion 2 Bottom part 21 Rear frame 22a Side frame 22b Side frame 23a Storage area 23b Storage area 3 pillars 31a Rear strut 31b Rear strut 31c front strut 31d front strut 41a Standing part 42a Standing part 43a Standing part 44a Standing part 41b Top plate 42b Top plate 43b Top plate 44b Top plate 41c Inner standing board 43c Inner standing board 5 Engagement part 51 Engaging part 52 Engaging part 53 Engaging part 54 Engagement part 500 Fixing fixtures 501 Spring 502 pins 502a Hook fittings 503 Plate 504 Type I Fixing Jig 6 Reflector 61 Reflector 62 Reflector 100 pallets 101 Palette 102 Palette 200 forklifts 201 Light-emitting part 202 Light receiving part

Claims

1. A pallet rack consisting of a rectangular parallelepiped shape with a rectangular frame on its top surface, which can be connected and stacked horizontally and vertically, The pallet mounting area formed on the upper surface is characterized by having a width in the left-right direction that is at least twice the width of the pallet. Pallet rack.

2. In the pallet rack described in claim 1, It is characterized by being disposed at the lower part of the rectangular parallelepiped shape, consisting of a U-shaped frame with an open front, and having a lower surface that is wider in the left-right direction than the upper surface. Pallet rack.

3. In the pallet rack described in claim 2, The rear frames of the upper and lower portions overlap in a plan view. Pallet rack.

4. In the pallet rack described in claim 3, The front support column is positioned at the front end of the lower surface, and the rear support columns are positioned at both the left and right rear ends of the upper surface. Pallet rack.

5. In the pallet rack described in claim 4, The aforementioned upper portion, A planar upper upright portion extending upward from the rear outer end face, A projection extending in a protruding manner from the upper end of the front support column, It is equipped with, The aforementioned lower portion is A hole-shaped structure is formed on the lower side of the front end, and a housing portion capable of accommodating the aforementioned projection is provided. Equipped with, When pallet racks are stacked and arranged, the upper lower portion is fixed to the upper upright portion located at the rear and below, and the upper storage portion accommodates and fixes the lower projection portion. Pallet rack.

6. In the pallet rack described in claim 5, Upright portions are formed in an upright shape and are symmetrically arranged on the left and right outer edges of the lower surface portion, The engagement portion consists of a through hole or notch formed in the upright portion, Equipped with, When pallet racks are arranged in a series, the two sets of upright sections are in surface contact with each other, and the two sets of upright sections are detachably fitted together with a fixing jig that allows the two sets of upright sections to be connected. Pallet rack.

7. In the pallet rack described in claim 1, It is characterized by having a reflector plate positioned on or near the rear support column, facing inward from the rectangular parallelepiped shape. Pallet rack.

Images