Kitted pallet rack upright frames

Abstract

The disclosed technology includes an upright frame for a pallet rack and the associated methods for assembling, storing, and shipping said frames. Each frame assembly comprises posts with a plurality of braces and components that may be pre-assembled prior to arriving at their assembly site, thereby reducing assembly time. The braces are designed to pivot within the posts, allowing for compact packaging and facilitating efficient shipment and assembly.

Description

KITTED PALLET RACK UPRIGHT FRAMESCROSS REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to US Provisional Patent Application No. 63 / 567,794, filed March 20, 2024. The entire contents of which is hereby incorporated by reference.FIELD

[0002] The present invention relates generally to storage pallet racks, and in particular a kitted pallet rack upright frame with bracing components configured for preinstallation.BACKGROUND

[0003] Pallet racks are used for warehousing and to provide shelving on which pallets, upon which goods are stored, are easily accessible for loading and removing by use of forklifts. Because of time and effort concerns, loading pallets onto racks by forklifts facilitates quick and easy placement and removal of the palleted goods from the rack. These concerns are especially relevant to the use of forklift loading in superstores or warehouse type stores, where pallets are loaded directly onto pallet racks for direct purchase by consumers.|0004] One primary aspect concerning these rack systems is their assembly. Conventional pallet rack systems can be cumbersome and time-consuming to assemble, often requiring a substantial number of separate components like upright frames, braces, and baseplates to be individually installed. Moreover, the process typically necessitates multiple installers and specialized tools. Furthermore, delivery and storage of these disassembled components can also prove challenging due to the volume of parts. The disassembled rack components must be sufficiently compact for shipping and storing prior to assembly, yet this typically complicates the assembly process by creating additional steps to unpack and sort all the individual components before installation begins. The upright frames could be assembled prior to shipping; however, this would occupy additional space and may result in damage to the upright frames and their components during shipping.

[0005] These issues illustrate a need in the field for a more efficient, time-saving, and securely stable pallet rack system that eases the burden of assembly, delivery, and storage, while also addressing stability concerns.SUMMARY

[0006] There is provided, in accordance with an example of the disclosed technology, a method of preassembling an upright frame of a pallet rack, comprising: preassembling a first upright frame assembly, comprising: coupling at least one first diagonal brace to a first post; coupling a first horizontal brace to the first post; and preassembling a second upright frame assembly, comprising: coupling at least one second diagonal brace to a second post; and coupling a second horizontal brace to the second post.

[0007] The at least one first diagonal brace can be coupled to the first post by one fastener provided through a through hole provided in the first post, and the at least one first diagonal brace is pivotably rotatable relative to the first post. Coupling the at least one first diagonal brace to the first post can include providing a fastener through holes provided at a first end of the at least one first diagonal brace and a first corresponding hole of the first post; and fastening the first end of the at least one first diagonal brace to the first post. Coupling the first horizontal brace to the first post can comprises providing a fastener through a hole provided at a first end of the first horizontal brace, a second corresponding hole of the first post, and a bushing; and fastening the first end of the first horizontal brace to the first post, where the first horizontal brace is pivotably rotatable relative to the first post. Coupling the at least one second diagonal brace to the second post can include providing a fastener through a hole provided at a first end of the at least one second diagonal braces and a first corresponding hole of the second post; and fastening the first end of the at least one second diagonal braces to the second post, where the at least one second diagonal brace is pivotably rotatable relative to the second post. Coupling the second horizontal brace to the second post can include providing a fastener through a hole provided at a first end of the second horizontal brace, a second corresponding hole of the second post, and a bushing; and fastening the first end of the second horizontal brace to the second post, and the second horizontal brace is pivotably rotatable relative to the second post.

[0008] The method may further comprise a step of indicating a corresponding hole on the first post for fastening a second end of the second horizontal brace. Indicating the corresponding hole on the first post for fastening the second end of the second horizontal brace can comprise providing a fastener in the corresponding hole. Indicating the corresponding hole on the first post for fastening the second end of the second horizontal brace can comprise providing visual indication on the first post at the corresponding hole. The method can further include fastening a first baseplate to a bottom of the first post and fastening a second baseplate to a bottom of the second post.[0009[ There is provided, in accordance with an example of the disclosed technology, a method of assembling the upright frame, with the steps of rotating a second end of the at least one first diagonal brace away from first post; coupling the at least one first diagonal brace to the second post; rotating a second end of the first horizontal brace away from the first post; coupling the first horizontal brace to the second post; rotating a second end of at least one second diagonal brace away from the second post; coupling the at least one second diagonal brace to the first post; and rotating a second end of the second horizontal brace away from the second post; and coupling the second horizontal brace to the first post.

[0010] The method can further include coupling a first end of a third horizontal brace to the first post and coupling a second end of the third horizontal brace to the second post. Coupling the third horizontal brace to the first post can include providing fastener through a hole provided at the first end of the third horizontal brace, a third corresponding hole of the first post, and a bushing; and fastening the first end of the at third horizontal brace to the first post. The second end of one of the at least one second diagonal brace can abut a first end of the first horizontal brace. The second end of one of the at least one first diagonal brace can abut a first end of the second diagonal brace.

[0011] There is provided, in accordance with an example of the disclosed technology, a method of packing the upright frame, by rotating the at least one first diagonal brace and the first horizontal brace to be approximately parallel with the first post; and rotating the least one second diagonal brace and the second horizontal brace to be approximately parallel with the second post.

[0012] At least a portion of the at least one first diagonal brace and the first horizontal brace can be disposed within the first post when rotated to be approximately parallel with the first post. The at least one first diagonal brace may be coupled to the first post by one fastener provided through a corresponding through hole provided in the first post. At least a portion of the at least one second diagonal brace and the second horizontal brace can be disposed within the second post when rotated to be approximately parallel with the second post. At least one first diagonal brace and the first horizontal brace can be fully disposed within an interior the first post when rotated to be approximately parallel with the first post. At least one second diagonal brace and the second horizontal brace can be fully disposed within an interior the second post when rotated to be approximately parallel with the second post. A bottom of the first post can have a first baseplate and a bottom of the second post can comprise a second baseplate; and the method of packing can further have the steps of rotating one of the first post or the second post prior to removably coupling the first post to the second post, such that the first baseplate of the first post is provided near a top of the second post when the first post and the second post are coupled together.

[0013] The method can further include removably coupling the first post and the second post such that the interior of the first post faces the interior of the second post. The method may further include removably coupling the first post and the second post such that the interior of the first post faces the exterior of the second post. The method may further include removably coupling the first post and the second post such that the interior of the second post faces the exterior of the first post.

[0014] There is provided, in accordance with an example of the disclosed technology, an upright frame of a pallet rack, comprising a first frame assembly, comprising: a first post, at least one first diagonal brace coupled to the first post, and a first horizontal brace coupled to the first post, and a second frame assembly, comprising a second post, at least one second diagonal brace coupled to the second post, and a second horizontal brace coupled to the second post.

[0015] The first post and the second post can be substantially c-shaped. The first post and the second post can each include an interior having a width greater than or approximately equal to twice the width of any one of one of the at least one first diagonal brace, the firsthorizontal brace, the at least one second diagonal brace, or the second horizontal brace. The upright frame can further comprise a third horizontal brace for coupling to the first post and the second post. The at least one first diagonal brace can be coupled to the first post by one fastener provided through a through hole in the first post.

[0016] The at least one first diagonal brace and the first horizontal brace can be rotatably coupled to the first post, and a majority length of the at least one first diagonal brace and the first horizontal brace can be disposed within an interior of the first post when the at least one first diagonal brace and the first horizontal brace are rotated to be substantially parallel to the first post The at least one second diagonal brace and the second horizontal brace can be rotatably coupled the second post, and a majority length of the at least one second diagonal brace and the second horizontal brace are disposed within an interior of the second post when the at least one second diagonal brace and the second horizontal brace are rotated to be substantially parallel to the second post. A first end of the second horizontal brace can be coupled to the second post by a fastener provided through a corresponding through hole in the second post, a hole in the first end of the second horizontal brace, and a bushing, and the bushing can be disposed within an interior of the second post. At least one of the at least one first diagonal brace, the at least one second diagonal brace, the first horizontal brace, and the second horizontal brace can be telescoping. At least of the at least one first diagonal brace, the at least one second diagonal brace, the first horizontal brace, and the second horizontal brace can be foldable.

[0017] There is provided, in accordance with an example of the disclosed technology, an upright frame of a pallet rack, comprising a frame assembly, where the frame assembly comprises a post, and at least one brace coupled to the post. The post can be substantially c- shaped. The post can comprise an interior with a width greater than or equal to twice the width of the at least one brace. The at least one brace can be rotatably coupled to the post such that a majority length of the at least one brace is disposed within the interior of the post when the at least one brace is rotated to be substantially parallel to the post. A first end of the at least one brace can be coupled to the post by a fastener provided through a through hole in the post, a hole in the first end of the brace, and a bushing. The bushing can be disposed within an interior of the post. The at least one brace can be telescoping and / or foldable. Packing theupright frame can comprise rotating the at least one brace to be approximately parallel with the post, and temporarily securing brace to the post such that it remains approximately parallel to the post during transportation. At least a portion of the brace can be disposed within the post when the brace is rotated to be approximately parallel with the post. Packing the brace and post can include wrapping the post and the at least one brace.10018] There is provided, in accordance with an example of the disclosed technology, a method of packing an upright frame assembly, where the upright frame assembly includes a first post and a second post. The first post and the second post can be substantially c-shaped. The upright frame assembly can further include at least one brace. The method of packing the upright frame assembly can include facing an open end of the first post towards an open end of the second post, placing the at least one brace within an interior portion of the first post or the second post; and securing the first post to the second post such that the at least one brace is stored between the first post and the second post during transportation. A first end of the at least one brace can be attached to the first post or the second post. The first post can be secured to the second post by at least one fastener. The at least one fastener can include a bolt and a nut, and the bolt can pass through a first hole provided in a rear side of the first post and a second hole provided in a rear side of the second post. A plate can be provided between the bolt and the rear side of the first post.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG. 1A depicts a generic representation of an assembled upright frame of a pallet rack, according to aspects of the present invention;

[0020] FIG. IB depicts a generic representation of an assembled pallet rack, according to aspects of the present invention;

[0021] FIGS. 2A-2C depict various stages of assembly of an upright frame of a pallet rack, according to aspects of the present invention;

[0022] FIG. 3 depicts a detailed schematic representation of an assembled upright frame of a pallet rack, with particular emphasis on the attachment mechanism of braces to posts, according to aspects of the present invention;

[0023] FIG. 4 depicts an exploded view of an exemplary embodiment of an upright frame of a pallet rack, according to aspects of the present invention;

[0024] FIG. 5 depicts an assembled view of an exemplary embodiment of an upright frame of a pallet rack, according to aspects of the present invention;

[0025] FIGS. 6A and 6B depict detailed schematic representations of connection made between post and brace components of an upright frame of a pallet rack, according to some embodiments;

[0026] FIGS. 7A-7E depict multiple exemplary configurations of upright frames of pallet racks, each with variations in design and measurements, according to aspects of the present invention; and

[0027] FIGS. 8A-8C depict components of an upright frame of a pallet rack configured for transportation, according to aspects of the present invention.DETAILED DESCRIPTION

[0028] The following detailed description should be read with reference to the drawings, in which like elements in different drawings are identically numbered. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. The detailed description illustrates by way of example, not by way of limitation, the principles of the invention. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives, and uses of the invention, including what is presently believed to be the best mode of carrying out the invention.

[0029] As used herein, the terms “about” or “approximately” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein. More specifically, “about” or “approximately” may refer to the range of values ±20% of the recited value, e.g., “about 90%” may refer to the range of values from 71% to 110%.

[0030] As discussed herein, a “user” can include operators, maintenance technicians, or any other individuals associated with assembling, packing, or shipping an upright frame of the pallet rack system.

[0031] FIG. 1A depicts a generic representation of an assembled upright frame 5 of a pallet rack. In some embodiments, the upright frame 5 comprises two posts: a first post 10 and a second post 20. Both posts are fundamentally similar in design and function but are designatedas “first” and “second” for ease of reference in installation and documentation. In some embodiments, as depicted in FIG. 1A, both the first 10 and second 20 posts serve as the primary vertical support structures for the assembled upright frame 5. In some embodiments, these posts are designed to be coupled with various types of braces 12, 14, to form the assembled upright frame 5. FIG. IB depicts generic representation an assembled pallet rack 1, according to some embodiments. An exemplary pallet rack 1 may comprise two assembled upright frames 5 connect by four beams 6 connected two and provided between the upright frames 5.

[0032] In some embodiments, the posts are substantially c-shaped or omega-shaped (Q- shaped). This mainly refers to the cross-sectional profile of the posts, which is approximately rectangular with one shorter side recessed or cut out, generating a form similar to a “C”, albeit with predominately straight lines and sharper corners. The posts may comprise three walls which form an interior portion of the post. The interior portion may be utilized to accommodate bracing and other components of the assembly, as described herein. In some embodiments, the substantially posts have a back side, two sidewalls, and an open front end. The open front end may be referred to as the interior side or portion of the post. The back side may be referred to as the rear or exterior side or portion of the post. The sidewalls of the post may be tapered or stepped inward.

[0033] In some embodiments, each post is constructed with multiple perforations or through holes which may serve as attachment points to facilitate the connection of various other components such as braces and baseplates. In some embodiments, these attachment points may take the form of perforations or pre-drilled holes. Some of the holes may be teardrop holes. These attachment points are designed to facilitate quick, secure connections while providing flexibility for adjustments and reconfigurations.

[0034] In some embodiments, as depicted in FIG. 1A, the upright frame 5 incorporates braces 12, 14, which serve to stabilize and transfer loads between the posts when assembled. In some embodiments, the braces span the distance between the two posts. The braces may be positioned either horizontally 14 or diagonally 12, relative to the floor, when fully assembled, as depicted in FIG. 1 A. Notably, these braces may intersect with each other at their attachment points with the posts. In some embodiments, these intersections may result in triangularconfigurations, as depicted in FIG. 1A, formed by the posts and the braces. This geometric arrangement may provide enhanced structural integrity to the frame.

[0035] FIGS. 2A-2C depict various stages of assembly of an upright frame 100 of a pallet rack which may be kitted, i.e., provided to a user with the necessary components to assemble and customize the frame. Figs. 2A-2B depict the upright frame 100 in a “pre-assembled” stage. This “pre-assembled” configuration refers to a configuration where some braces are connected to and can pivot inside of a single post, but the two posts are not yet connected to each other. The objective of this pre-assembled configuration is to reduce the complexity and the number of assembly tasks that will need to be performed during assembly, thereby minimizing the overall time and effort required for complete assembly.

[0036] In some embodiments, pre-assembly involves integrating various sub-components into larger structural units. For example, this could mean attaching braces to one of the posts prior to shipping, so that these pre-assembled units can be quickly aligned, joined, and secured with the remaining components during the final assembly stage. In some embodiments, preassembly may also encompass the application of fasteners or other connection means to the braces and / or posts. It may further include the pre-drilling of holes or the pre-attachment of hardware like bushings.

[0037] In some embodiments, “pre-assembly” refers to the process of assembling designated components of a pallet rack frame at a first location, separate from the installation site or final destination. A pre-assembled upright frame may, for example, encompass various configurations, such as coupling at least two diagonal braces to a first post; coupling a horizontal brace to the same post; coupling at least one other diagonal brace to a second post; and coupling at least one other horizontal brace to the second post.

[0038] In some embodiments, “partial assembly” refers to the coupling of only some of the components of an upright frame at a first location. Thus, not all designated elements that make up the complete upright frame are necessarily connected during partial assembly. This provides increased flexibility for transport, storage, and final assembly. For example, a partial assembly may involve coupling only one horizontal brace to a first post, while leaving diagonal braces for later attachment. Partial assembly may alternatively involve coupling onlyone diagonal brace to a second post, while leaving other horizontal braces separate for later attachment. Further, partial assembly may involve coupling a baseplate to each of the posts. [00391 The purpose of facilitating a partial assembly is multifold. Partial assemblies are often easier to transport than individual loose components, and thus they may be more stable and less prone to movement or damage during shipping. Partially assembled units can simplify and expedite the final on-site assembly steps. Depending on the end user’s requirements or the conditions of the installation site, partial assemblies can be customized to allow for flexible integration with other system components. Partial assemblies also may allow for easier scaling of the storage system, offering modularity that enables users to expand or contract the overall structure as needed. The state of being partially assembled is usually temporary and exists as a transitional phase between the manufacturing and final installation stages.

[0040] In some embodiments, the term “pre-shipping” refers to a specific stage within the supply chain and production cycle of the upright frame. In this stage, components - whether individual or in the form of partial assemblies - are in a state of readiness for transit but have not yet been dispatched for shipment to their final installation site.

[0041] In some embodiments, “pre-shipping” refers to the activities performed on the preassembled or partially assembled upright frame components to prepare them for transport to the installation site or final destination. This may involve packing methods, such as rotating at least two diagonal braces and a horizontal brace to be approximately parallel with and housed within a first post; rotating at least one other diagonal brace and a second horizontal brace to be approximately parallel with and housed within a second post. The aim of preshipping is to ensure that the pre-assembled or partially assembled components are optimally configured for space-efficient, secure, and safe transportation.

[0042] FIGS. 2A-2B depict exemplary embodiments of an upright frame 100 of a pallet rack in a state of pre-assembly. In this example, a first 110 and second 120 post may be coupled with a subset of braces 112 114 122 124. In some embodiments, baseplates 140 are coupled to the posts.

[0043] In some embodiments, as depicted in FIGS. 2A-2B, multiple horizontal and diagonal braces are coupled to the posts 110 120. For example, FIGS. 2A-2B depict braces 112 114 coupled to a first post 110 and braces 122 124 coupled to a second post 120. In someembodiments, a distinct horizontal brace 134 is not attached to either post during the preassembly stage. The first post 110 with braces 112 114 coupled to the post may be referred collectively referred to as a first frame assembly. The first post 120 with braces 122 124 coupled to the post may be referred collectively referred to as a second frame assembly.

[0044] FIG. 2C depicts an exemplary upright frame 100 of a pallet rack in a fully assembled state. In this example, two posts 110 120 are positioned parallel to each other, and with baseplates 140 attached to the bottom ends of the posts. FIG. 2C also depicts the implementation of multiple horizontal and diagonal braces 112 114 122 124.

[0045] In some embodiments, as depicted in FIG. 2C, the configuration includes three horizontal braces 114 124 134 and multiple diagonal braces 112 122. In some embodiments, the horizontal braces are employed to provide lateral stability to the upright frame 100. In FIG. 2C, the horizontal braces are situated parallel to the level of the floor and are positioned at specified intervals along the height of the posts. These braces connect the parallel posts 110 120, thereby creating a frame within which pallets or other storage items can be housed. In some embodiments, multiple diagonal braces 112 122 also connect the parallel posts 110 120, and function to provide both lateral and torsional stability to the upright frame 100.

[0046] In the exemplary embodiment as depicted in FIG. 2C, the bottom-most, or first, horizontal brace 114 is pre-attached to the first post 110 and extends to and connects with the second post 120. Positioned above this first horizontal brace 114 is a second diagonal brace 122, connected to the second post 120 in the pre-assembly stage, which extends to and connects with the first post 110 in the fully-assembled stage. As depicted in FIG. 2C, this second diagonal brace 122 is connected to the first post 110 at the same position as the first horizontal brace 114 and connects at an elevated point on the second post 120. Additional, or first, diagonal braces 112, originating from the first post 110 in the pre-assembly stage, extend to two separate points on the second post 120 in the fully assembled state. The connection point of one of said first diagonal braces 112 on the second post 120 coincides with the attachment point of the aforementioned second diagonal brace 122. The connection point of the other of said first diagonal braces 112 on the second post 120 coincides with the attachment point of a higher, third horizontal brace 134. Positioned above these diagonal braces is a separate middle, or third, horizontal brace 134 that, during the final assembly, attaches to bothposts 1 10 120. This third horizontal brace 134 aligns on the second post 120 at the same height as the connection point of one of the previously mentioned first diagonal braces 112. Lastly, the second horizontal brace 124, pre-attached to the second post 120, is shown in FIG. 2C to connect to the first post 110 above the previously mentioned third horizontal 134 in this exemplary assembled configuration.

[0047] FIG. 3 depicts a detailed schematic representation of an assembled upright frame 100 of a pallet rack, with particular emphasis on the attachment mechanism of braces to posts. The upright frame 100, similar to the previously described figures, comprises vertically oriented posts 110 120, each designed with perforations or attachment points, as well as diagonal and horizontal braces 112 114 122 124 134.

[0048] In some embodiments, as depicted in FIG. 3, an array of braces spans between these vertical posts. A horizontal brace 114, situated near the base of the frame, runs parallel to the ground, and it extends between the two vertical upright posts. Another horizontal brace 134, positioned at a higher elevation, also extends between the two vertical upright posts. An uppermost horizontal brace 124 connects elevated sections of the vertical posts. A diagonal brace 122 commences from the second post 120 and traverses diagonally to meet the first post 110 at a point coinciding with the attachment of the horizontal brace 114. Additional diagonal braces 112 commence from the first post 110 and traverse diagonally to meet the second post 120 at two different points.

[0049] In some embodiments, as depicted in FIG. 3, some of the braces are arranged in a triangulated structure which provides inherent mechanical advantages. The inclusion of a diagonal brace or diagonal braces in conjunction with the vertical parallel posts and the horizontal braces forms a series of interconnected triangles between the posts. This formation resists deformation under load because its sides and angles are interdependent. The diagonal brace(s) also confers torsional rigidity, preventing twisting movements around the vertical axis of the posts. This feature is especially beneficial in situations where the system is subject to unevenly distributed load or dynamic forces. In some examples, each diagonal brace forms an angle of approximately 45 degrees relative to the posts to which is attached. In some examples, each diagonal brace forms an angle of approximately 30 to 60 degrees relative to the posts to which is attached.

[0050] In some embodiments, as depicted in FIG. 3, a baseplate 140 is present at the base of each of the posts 110 120. The baseplate 140 serves as the foundational component for the upright frame 100, facilitating the anchoring of the posts 110 120 to the ground. This ensures stability and securement of the entire upright frame 100 under variable loading conditions. In essence, the baseplate 140 functions as the interface between the upright assemblies and the ground.

[0051] In some embodiments, the baseplates 140 are typically comprised of two components a flat, rectangular base, and a perpendicular component that connects the base to the posts 110 120. The flat, rectangularprovides a stable surface for anchoring the upright frame to the floor. The perpendicular component extends upward from this base, aligning with the post and providing a connection point for the post to securely attach. In some embodiments, as depicted in FIG. 3, the baseplates 140 are secured to their respective post via a fastener 150 through a hole provided in the perpendicular aspect of the baseplate 140. Additionally, the baseplates 140 may feature pre-drilled holes or slots that allow for secure anchoring to the floor using appropriate fastening mechanisms such as, but not limited to, bolts or concrete anchors. In some embodiments, the dimensions of the baseplate may vary based on the calculated load and stability requirements, as well as any applicable safety factors.

[0052] In some embodiments, various baseplate sizing options are available. For example, in some embodiments, various baseplate sizing options are available in dimensions ranging from about 4-inches by 4-inches to about 8-inches by 8-inches. The rationale for this variability is that different geographic locations have unique seismic activity profiles; larger baseplates increase the stability of the system under lateral forces, such as those experience during an earthquake. For example, in a location like New York, which has a lower seismic hazard profile, a 4-inch by 4-inch baseplate may suffice. Conversely, in an area like California, which is known for higher seismic risks, an 8-inch by 8-inch baseplate may be more appropriate.

[0053] FIG. 3 also depicts the utilization of fasteners for the purpose of coupling the braces to the upright posts. In some embodiments, a fastener 151 is provided through holes on the end of a brace and on a post. In some embodiments, the fastener 151 is also provided through a bushing 155 that is disposed within the interior of a post. In some embodiments, the bushing155 is positioned at the junctures where the braces intersect the posts. This mitigates direct metal-on-metal contact between the brace and the post, thus minimizing wear and tear stemming from routine operational stresses.

[0054] In some embodiments, the fastener is a screw-type fastener 151 (e.g., a threaded bolt) that fastens to a nut 152, thus fastening the ends of a brace to a post. In some embodiments, these fasteners fit into the perforations of the posts, ensuring that the braces remain anchored. The enlarged views provided in FIG. 3 illustrates the interplay between the fasteners 150 151, the nut 152, the bushings 155, the braces 124, and the posts 110 120.

[0055] In some embodiments, common connection points between braces will share a single fastener, bolt, or connection mechanism. In some embodiments, brace ends that do not share another brace will have a bushing 155 in the resulting gap. The bushing 155 may prevent lateral movement of the brace along the fastener when secured.

[0056] FIG. 4 depicts an exploded view of an exemplary embodiment of an upright frame 100 of a pallet rack. In an exemplary embodiment, as depicted in FIG. 4, two vertically posts are present; a first post 110 and a second post 120. In some embodiments, three horizontal braces are present in the upright frame 100. The uppermost, or second, horizontal brace 124 is located towards the top of and spans the posts. Another brace, the third horizontal brace 134, is located below the second horizontal brace 124 and also spans the posts. The bottommost, or first, horizontal brace 114, is situated closer to the base of the vertical posts. In some embodiments, diagonal braces further add to the frame’s robustness. Two braces, the first two diagonal braces 112, originate from the first post 110 and extend in two distinct directions to two separate points on the second post 120. This forms a triangular configuration that provides added stability. Another diagonal brace, the second diagonal brace 122, spans from the second post 120 and intersects with the first post 110 at a point coinciding with the attachment point of the first horizontal brace 114.

[0057] In some embodiments, as depicted in FIG. 4, broadened platforms, or baseplates 140, are situated at the base of each post. These baseplates 140 serve to distribute the weight and mechanical loads exerted on the upright frame 100, thereby minimizing the risk of tipping and ensuring enhanced stability. Further, the baseplates 140 comprise through holes for appropriate fastening mechanisms to anchor the posts to the floor.

[0058] In some embodiments, as depicted in FIG. 4, an interior 1 16 126 and exterior 118 128 of each post 110 120 is present. In some embodiments, the interior 116 of the first post 110 is where the braces can be fully concealed when rotated to align within the post. This design emphasizes the notion of a shielded configuration. The exterior 118 of the first post 110 is structured such that, under certain configurations, it may be positioned to face the interior 126 of the second post 120 when the posts are interconnected.

[0059] In some embodiments, the design of the second post 120 mirrors the first 110 in terms of its interior and exterior features. The interior 126 of the second post 120 is constructed to accommodate the braces when they are rotated to be parallel with the post, emphasizing a protective design.

[0060] FIG. 4 further illustrates the use of bushings 155 and fasteners to secure the braces to the posts. In some embodiments, the design incorporates bushings 155 as a component of the coupling mechanism. In some embodiments, a fastener couples the end of a brace to a post. In some embodiments, the design includes a through-hole in the post, a hole in the end of the brace, a fastener, and a bushing. In some embodiments, the fastener and / or the bushing assembly is disposed within the interior of the post.

[0061] FIG. 5 depicts an assembled view of an exemplary embodiment of an upright frame 100 of a pallet rack. In the exemplary embodiment as depicted in FIG. 5, two vertically posts are present; a first post 110 and a second post 120. In some embodiments, three horizontal braces are present in the upright frame 100. The uppermost, or second, horizontal brace 124 is located towards the top of and spans the posts. Another brace, the third horizontal brace 134, is located below the second horizontal brace 124 and also spans the posts. The bottommost, or first, horizontal brace 114, is situated closer to the base of the vertical posts. In some embodiments, diagonal braces further add to the frame’s robustness. Two braces, the first two diagonal braces 112, originate from the first post 110 and extend in two distinct directions to two separate points on the second post 120. This forms a triangular configuration that provides added stability. Another diagonal brace, the second diagonal brace 122, spans from the second post 120 and intersects with the first post 110 at a point coinciding with the attachment point of the first horizontal brace 114. In some embodiments, broadened platforms, or baseplates 140, are situated at the base of each post.

[0062] FIGS. 6A and 6B depict details of the connection of braces 112 to a post 110, according to some embodiments. Each post 110 may comprise be substantially omega-shaped and have two side walls 117 which taper or step inward. Each side wall 117 may comprise two sets of holes 162 164. A first set of holes 162 of the sidewalls may be utilized for attachment of a beam (e.g., beam 6 as depicted in FIG. IB) to the post 110. A second set of holes 164 may be utilized for attaching braces 112. As depicted in FIG. 6A, the interior 116 of the post 110 may be wide enough to accommodate two braces 112. The braces 112 may comprise through holes at their ends to receive a bolt 151 and can be secured into position on the post 110 by placing the bolt 151 through a hole 164 and threading the bolt into a corresponding nut 152. In some embodiments, as depicted in FIG. 6A, the braces 112 may be substantially c-shaped and may be assembled back-to-back when secured onto the post. With reference to FIG. 6B, a single brace 112 may be secured using a bolt threaded into a corresponding nut 152. Additionally, a bushing or spacer 155 may be utilized to prevent lateral movement of the brace 112 along the length of the bolt 151.

[0063] FIGS. 7A-7E depict multiple exemplary configurations of upright frames of pallet racks, each with variations in design and measurements. Each configuration showcases an upright frame that comprises two posts, braces connecting these posts, and baseplates.

[0064] In some embodiments, variations in the overall height of the upright frames are present. In some embodiments, the vertical distance between the diagonal braces and the horizontal braces, as well as the vertical distance between the horizontal braces, may vary across different embodiments. FIGS. 7A-7E depict exemplary measurements of the vertical distance between the horizontal brace and the top of the posts. FIG. 7A-7E further depict exemplary embodiments of the horizontal distance between the interior of the vertical posts and the horizontal distance between the exterior of the vertical posts. Variations in these distances across FIGS. 7A-7E indicate different potential storage widths, which can accommodate varied item sizes and quantities.

[0065] In some embodiments, as depicted in FIG. 7A, the height 174 of the upright frame may be 96 inches tall and width 172 may be 48 inches wide. In some embodiments, as depicted in FIG. 7B, the height 174 of the upright frame may be 120 inches tall and the width 172 may be 42 inches wide. In some embodiments, as depicted in FIG. 7C, the height 174 of the uprightframe may be 120 inches tall and width 172 may be 48 inches wide. In some embodiments, as depicted in FIG. 7D, the height 174 of the upright frame may be 144 inches tall and the width 172 may be 42 inches wide. In some embodiments, as depicted in FIG. 7E, the height 174 the upright frame may be 192 inches tall and the width 172 may be 42 inches wide.

[0066] In some embodiments, the quantity of diagonal bracing is quantified by the height of the uprights. In some embodiments, as depicted in FIG. 7A, there may be three horizontal braces and three diagonal braces. In some embodiments, as depicted in FIG. 7B, there may be three horizontal braces and four diagonal braces. In some embodiments, as depicted in FIG. 7C, there may be three horizontal braces and five diagonal braces. In some embodiments, as depicted in FIG. 7D, there may be three horizontal braces and five diagonal braces. In some embodiments, as depicted in FIG. 7E, there may be three horizontal braces and seven diagonal braces.

[0067] In some embodiments, the quantity of triangles formed by the diagonal bracing is quantified by the height of the uprights. In some embodiments, as depicted in FIG. 7A, there may be two isosceles triangles formed by three diagonal braces. In some embodiments, as depicted in FIG. 7B and 6C, there may be three isosceles triangles formed by four diagonal braces. In some embodiments, as depicted in FIG. 7D, there may be four isosceles triangles formed by five diagonal braces. In some embodiments, as depicted in FIG. 7E, there may be six isosceles triangles formed by seven diagonal braces. Depending on the angle at which the diagonal bracing is provided at relative to the post, said isosceles triangles may further be equilateral triangles where one side of the triangle, formed by the post, is about equal to the length of each diagonal brace. Further, a right triangle may be formed by a diagonal brace and a horizontal brace. Said right triangle may be approximately half the size of the isosceles triangles formed by two diagonal braces.

[0068] In some embodiments, the braces may be foldable. The inclusion of foldable braces in the upright frame system serves dual purposes of enhancing portability and minimizing storage space. In some embodiments, each foldable brace is designed with one or more hinge points along its length, typically situated at the midpoint or at strategically defined intervals, allowing for the brace to be manually folded. In some embodiments, the folding is along the longitudinal axis, causing the brace to collapse into a configuration approximately half itsextended length. Notably, each foldable brace may incorporate a fastener or locking means situated near its midpoint or at predetermined positions. This locking means is operable to lock the brace in its extended state. The locking mechanism could include, but is not limited to, components such as fasteners, locking pins, clamp systems, or threaded screw mechanisms.

[0069] In some embodiments, the braces may be telescoping. In some embodiments, a telescoping brace may comprise an inner tube and an outer tube. The inner tube slides within the outer tube to provide adjustable lengths. The telescoping method thus allows for the ease of reconfiguration and adaptability to different storage or loading conditions. In some embodiments, each telescoping brace includes a locking mechanism, which could be situated at the midpoint or along the length of the brace at predetermined intervals. This locking mechanism ensures that the telescoping brace remains in its chosen length, thereby ensuring that the structure remains stable and secure, even under varying load conditions. The locking mechanism could include, but is not limited to, components such as fasteners, locking pins, clamp systems, or threaded screw mechanisms that engage both the inner and outer tubers.

[0070] In some embodiments, the concept of pre-assembly, as previously described, pertains to the preparation of individual components in a manner that facilitates quicker and more efficient final assembly at the installation site. Various methods of pre-assembly can be employed depending on the dimensions, weight constraints, and intended application of the upright frame.

[0071] In some embodiments, particularly those comprising smaller upright frame sizes or those designed for lighter loads, all braces can be pre-attached to one of the posts. This method minimizes the number of components that need to be handled during the final assembly. In some embodiments, only a subset of the braces is pre-attached to the posts. This could be just the horizontal braces, just the diagonal braces, or a combination of both. This method of preassembly allows for greater flexibility in shipping and storage while still reducing some of the labor required for the final assembly. In some embodiments, modular components such as the baseplates could be pre-assembled as separate units. In some embodiments, the baseplate might be pre-attached to the posts prior to shipping. In some embodiments, all locking mechanisms may be pre-installed into the posts and / or braces.

[0072] As an exemplary embodiment, for smaller upright frame sizes in particular, the most efficient approach may be to pre-attach all braces to one of the posts. This would involve both the horizontal and diagonal braces being attached to a single post, thereby forming a partially assembled unit that only requires attachment to the second post for completion. This preassembled unit could be packed in a manner that protects the pre-attached components during shipping.

[0073] In an exemplary embodiment, the simplest form of the assembly includes two vertically oriented posts, three horizontal braces, and a single diagonal brace. In this embodiment, each post is designed with a series of perforations or attachment points to allow for the attachment of braces and baseplates. In this embodiment, the uppermost horizontal brace is positioned near the top of the two posts and spans between them. The middle horizontal brace is situated below the uppermost horizontal brace and spans the two posts. The lowermost horizontal brace is located near the base of the posts, also spanning between them. In this embodiment, the single diagonal brace originates from a point near the bottom of the first post, intersecting with the lowermost horizontal brace, and extends diagonally to intersect with the second post at a point coinciding with the attachment of the middle horizontal brace.

[0074] In some embodiments, the method of pre-assembly and packing of the upright frame system offers options for convenient transportation and storage of the components.

[0075] Packing of the upright frame system may include coupling a first post of the upright frame system to a second post of the upright frame system. Coupling of the first post to the second post may comprise using ties, tape, shrink-wrap, or other suitable methods of temporary attachment. FIG. 8A depicts a method of packing an upright frame. In some embodiments, a first post 110 and a second post 120 are secured to one another for packing and shipping. The first post 110 and the second post 120 may be fastened to one another using fasteners such as a bolt 153 and a corresponding nut 154. In some embodiments, the first post 110 and the second post 120 are arranged such that the interiors sides of the posts face one another, and one or more bolts are provided through holes on the rear sides of the posts and secured in place with a nut 154. As depicted in FIG. 8B, arrangement provides a space within the combined interiors of the posts for the other components of the upright frames, such asthe braces 112, bolts 151 , nuts 152, and spacers / bushings (e g., spacers / bushings 155 as depicted in FIGS. 3 and 6B), to be placed within the posts for packing and shipping. In some embodiments, the bolts 153 used for packing securing the posts to one another are larger than the bolts 151 used to secure the braces 112 onto the posts. In some embodiments, additionally or alternatively, ties 156 are used to secure the posts to one another. The ties 156 may be metal, nylon, zip-ties, or other suitable means to secure the posts to one another.

[0076] As depicted in FIG. 8C, a packing plate 158 may be used in conjunction with bolts 153 to secure the bolts to one another. The packing plate 158 may be utilized to disperse stress concentrations across the rear of the posts 110 to prevent deformation of the posts when the bolts 153 are tightened. In some embodiments, two bolts 153 and a plate 158 are provided at each end of the posts to secure the posts together. In some embodiments, another plate is provided to abut the corresponding nut. In some embodiments, a space 159 is provided on the plate which may be engraved or otherwise marked to serve as an indication of which end of the post is up or down, and / or utilized as a space for branding. In some embodiments, the baseplate 140 is attached to the post 110 below the bolts 153 and plate 158 used to secure the posts to one another. Providing two through holes on said plate 158 to receive bolts 153 may allow for the plate 158 to be secured in position without having to provide a teardrop shaped protrusion to correspond to the teardrop shaped holes provided on an outer surface of the post 110.

[0077] In some embodiments, packing and shipping of a replacement upright frame components may be desirable. A replacement component may include a post having at least one brace rotatably coupled to the post. The replacement components may be desirable for replacing components of the upright frame system damaged during loading, for example, by a collision with a forklift. Packing a replacement post and brace may include using ties, tape, shrink-wrap, or other suitable methods of temporary attachment to keep a portion of the brace withing the interior of the post. In some examples, the replacement post and brace may be wrapped in bubble wrap or foam wrap to temporarily secure the brace to the post and prevent damage during shipping. The wrapped replacement post and brace may be placed in a box to further prevent damage during shipping.

[0078] As previously described, the bottoms of the first and second posts may comprise baseplates. When these posts are prepared for packing, one post may be rotated such that its baseplate is positioned near the top of the other post upon coupling. This stacking configuration serves to reduce the footprint of the packed system, making it more compact and manageable for both storage and transportation. The rotated positioning also allows for enhanced stabilization of the coupled posts, as the baseplate of one post can act as a supplementary anchor point when affixed near the top of the other. In some embodiments, the baseplates are positioned on the same ends of the posts when the posts are secured together for shipping.

[0079] In some embodiments, the first and second posts can be removably coupled such that the interior of the first post faces the interior of the second post. This method allows the cavities of the posts to be co-aligned, offering a continuous hollow space that may be useful for inserting additional packing materials or components. Moreover, this method facilitates a tighter packing configuration, making the most of available storage and transportation space.

[0080] In some embodiments, alternative alignments between the interior and exterior surface of the first and second posts may exist. In some embodiments, the interior of the first post faces the exterior of the second post. Conversely, in some embodiments, the interior of the second post may face the exterior of the first post. These varied orientations provide different benefits depending on specific requirements, such as maximizing structural stability or accommodating various types of additional packing materials.

[0081] In some embodiments, various methods may be employed to pre-assemble the braces, depending on factors such as the dimensions of the upright frames, intended load capacity, and specific shipping or storage constraints. Below are a few exemplary approaches to the pre-assembly of braces.

[0082] In some embodiments, for smaller upright frame sizes or designs intended for lighter loads, the most efficient approach may involve pre-attaching all braces to one of the posts. In this method, both the uppermost, middle, and bottom-most horizontal braces along with the diagonal braces would be pre-attached to, for instance, the first post. This results in a partially assembled unit that would only require attachment to the second post and baseplate for completion. This pre-assembled configuration reduces the number of separate componentsthat need to be handled during final assembly, thereby minimizing both assembly time and the risk of component damage or misplacement. Additionally, this pre-assembled unit can be packed in a manner that protects the pre-attached components during shipping.

[0083] In some embodiments, it may be beneficial to only pre-attach a subset of the braces to one of the posts. For example, only the horizontal braces, only the diagonal braces, or a combination of either might be pre-attached to the first post. This approach provides a middle ground, still reducing the number of components that must be individually handled during final assembly, while allowing for greater flexibility in shipping and storage configurations.

[0084] In some embodiments, especially those designed for heavier loads or specialized applications, modular components such as telescoping braces or specialized baseplates may be pre-assembled as separate units. These modules could then be quickly and easily attached to the posts at the final installation site. Modular pre-assembly offers the advantage of simplifying the final assembly without unduly complicating shipping or storage.

[0085] In some embodiments, all required locking mechanisms, such as screws, bolts, or specialized fasteners, may be pre-installed into the posts or braces. This eliminates the need for separate fastening components to be shipped and handled during assembly, thereby reducing the complexity and duration of the final assembly process. In some examples, preinstalled fasteners may serve as indicators for positioning the free end of a corresponding brace which is pre-installed on an opposing post. In some examples, another visual indicator, such as a sticker or marking may be provided for indicating an attachment point of a free end of a corresponding brace which is pre-installed on an opposing post. Braces and their attachment points on the posts can be color-coded. Thus, for example a green colored brace or distal end of a brace can be aligned to a green “hole” that receives the locking mechanism on the post. This can add to the simplicity of assembly.

[0086] The disclosed technology described herein can be further understood according to the following clauses:

[0087] Clause 1 : A packaged upright frame of a pallet rack, comprising: a first post; a second post temporarily attached to the first post; and at least one brace.

[0088] Clause 2: The packaged upright frame of Clause 1, wherein the first post is attached to the second post by at least one fastener. 1

[0089] Clause 3: The packaged upright frame of Clause 2, wherein the at least one fastener comprises a bolt and a nut.[0090| Clause 4: The packaged upright frame of Clause 3, wherein the bolt passes through a first hole provided in a rear side of the first post and a second hole provided in a rear side of the second post.

[0091] Clause 5: The packaged upright frame of Clause 4, wherein a plate is provided between the bolt and the rear side of the first post.

[0092] Clause 6: The packaged upright frame of any one of Clauses 1 to 5, wherein an open end of the first post faces towards an open end of the second post when the first post is attached to the second post.

[0093] Clause 7: The packaged upright frame of Clause 6, wherein the at least one brace is provided in a space provided by an interior portion of the first post and / or an interior portion of the second post.

[0094] Clause 8: The packaged upright frame of any one of Clauses 1 to 7, wherein the at least one brace is attached to the first post or the second post.

[0095] Clause 9: A method of packing an upright frame assembly, the upright frame assembly comprising: a first post; a second post, the first post and the second post comprising a substantially c-shaped cross-section; and at least one brace; and the method of packing the upright frame assembly, comprising: placing the at least one brace within an interior portion of the first post or the second post; and securing the first post to the second post.

[0096] Clause 10: The method of Clause 9, wherein a first end of the at least one brace is attached to the first post or the second post.

[0097] Clause 11 : The method of Clause 9 or 10, wherein the first post is secured to the second post by at least one fastener.

[0098] Clause 12: The method of Clause 11, wherein the at least one fastener comprises a bolt and a nut.

[0099] Clause 13: The method of Clause 12, wherein the bolt passes through a first hole provided in a rear side of the first post and a second hole provided in a rear side of the second post.

[0100] Clause 14: The method of Clause 13, wherein a plate is provided between the bolt and the rear side of the first post.[01011 Clause 15: The method of any one of Clauses 9 to 14, further comprising a step of facing an open end of the first post towards an open end of the second post prior to securing the first post to the second post.

[0102] Clause 16: The method of Clause 15, wherein the at least one brace is provided in a space provided by the interior portion of the first post and / or an interior portion of the second post.

[0103] Clause 17: An upright frame assembly of a pallet rack, comprising: a post; and at least one brace coupled to the post.

[0104] Clause 18: The upright frame assembly of Clause 17, wherein the post is substantially c-shaped.

[0105] Clause 19: The upright frame assembly of Clause 17 or 18, wherein the post comprises an interior having a width greater than or approximately equal to twice the width of the at least one brace.

[0106] Clause 20: The upright frame assembly of any one of Clauses 17 to 19, wherein the at least one brace is rotatably coupled to the post, and wherein a majority length of the at least one brace is disposed within an interior of the post when the at least one brace is rotated to be substantially parallel to the post.

[0107] Clause 21 : The upright frame assembly of any one of Clauses 17 to 20, wherein a first end of the at least one brace is coupled to the post by a fastener provided through a corresponding through hole in the post, a hole in the first end of the brace, and a bushing, wherein the bushing is disposed within an interior of the post.

[0108] Clause 22: The upright frame assembly of any one of Clauses 17 to 21, wherein the at least one brace is telescoping.

[0109] Clause 23: The upright frame assembly of any one of Clauses 17 to 21, wherein at least one of the at least one brace is foldable.

[0110] Clause 24: A method of preassembling an upright frame of a pallet rack, comprising: preassembling a first post assembly, comprising: coupling at least one first diagonal brace to a first post; coupling a first horizontal brace to the first post; and preassembling a second postassembly, comprising: coupling at least one second diagonal brace to a second post; and coupling a second horizontal brace to the second post.[01 H | Clause 25: The method of Clause 24, wherein the at least one first diagonal brace is coupled to the first post by one fastener provided through a through hole provided in the first post, wherein the at least one first diagonal brace is pivotably rotatable relative to the first post.

[0112] Clause 26: The method of Clause 24 or 25, wherein coupling the at least one first diagonal brace to the first post comprises: providing a fastener through a hole provided at a first end of each of the at least one first diagonal brace and a first corresponding hole of the first post; and fastening the first end of the at least one first diagonal brace to the first post.

[0113] Clause 27: The method of any one of Clauses 24 to 26, wherein coupling the first horizontal brace to the first post comprises providing a fastener through a hole provided at a first end of the first horizontal brace, a second corresponding hole of the first post, and a bushing; and fastening the first end of the first horizontal brace to the first post, wherein the first horizontal brace is pivotably rotatable relative to the first post.

[0114] Clause 28: The method of any one of Clauses 24 to 27, wherein coupling the at least one second diagonal brace to the second post comprises: providing a fastener through a hole provided at a first end of the at least one second diagonal braces and a first corresponding hole of the second post; and fastening the first end of the at least one second diagonal braces to the second post, wherein the at least one second diagonal brace is pivotably rotatable relative to the second post.

[0115] Clause 29: A method of assembling an upright frame, the upright frame comprising: a first post; at least one first diagonal brace coupled to the first post at a first end; at least one first horizontal brace coupled to the first post at a first end; a second post; at least one second diagonal brace coupled to the second post at a first end; at least one second horizontal brace coupled to the second post at a first end; the method comprising: rotating a second end the at least one first diagonal brace away from first post; coupling the second end of the at least one first diagonal brace to the second post; rotating a second end of the first horizontal brace away from the first post; coupling the second end of the first horizontal brace to the second post; rotating a second end of at least one second diagonal brace away from the second post;coupling the second end of the at least one second diagonal brace to the first post; and rotating a second end of the at least one second horizontal brace away from the second post; and coupling the second end of the at least one second horizontal brace to the first post.[0H6| Clause 30: The method of Clause 29, further comprising a step of indicating a corresponding hole on the first post for fastening a second end of the second horizontal brace.

[0117] Clause 31 : The method of Clause 30, wherein indicating the corresponding hole on the first post for fastening the second end of the second horizontal brace comprises providing a fastener in the corresponding hole.

[0118] Clause 32: The method of Clause 30, wherein indicating the corresponding hole on the first post for fastening the second end of the second horizontal brace comprises providing visual indication on the first post at the corresponding hole.

[0119] Clause 33: The method of any one of Clauses 24 to 32, further comprising fastening a first baseplate to a bottom of the first post and fastening a second baseplate to a bottom of the second post.

[0120] Clause 34: A method of packing the upright frame the upright frame comprising: a first post; at least one first diagonal brace coupled to the first post at a first end; at least one first horizontal brace coupled to the first post at a first end; a second post; at least one second diagonal brace coupled to the second post at a first end; at least one second horizontal brace coupled to the second post at a first end; the method comprising: rotating the at least one first diagonal brace and the first horizontal brace to be approximately parallel with the first post; and rotating the least one second diagonal brace and the second horizontal brace to be approximately parallel with the second post.

[0121] Clause 35: The method of Clause 34, further comprising coupling a first end of a third horizontal brace to the first post and coupling a second end of the third horizontal brace to the second post.

[0122] Clause 36: The method of Clause 35, wherein coupling the third horizontal brace to the first post comprises providing fastener through a hole provided at the first end of the third horizontal brace, a third corresponding hole of the first post, and a bushing; and fastening the first end of the third horizontal brace to the first post.

[0123] Clause 37: The method of Clause 35 or 36, wherein the second end of one of the at least one second diagonal brace abuts a first end of the first horizontal brace.

[0124] Clause 38: The method of any one of Clauses 35 to 37, wherein the second end of one of the at least one first diagonal brace abuts a first end of the second diagonal brace.

[0125] Clause 39: A method of packing the upright frame of any one of Clauses 17 to 23, comprising: rotating the at least one first diagonal brace and the first horizontal brace to be approximately parallel with the first post; and rotating the least one second diagonal brace and the second horizontal brace to be approximately parallel with the second post.

[0126] Clause 40: The method of Clause 39, wherein at least a portion of the at least one first diagonal brace and the first horizontal brace are disposed within the first post when rotated to be approximately parallel with the first post.

[0127] Clause 41 : The method of Clause 39 or 40, wherein the at least one first diagonal brace is coupled to the first post by one fastener provided through a corresponding through hole provided in the first post.

[0128] Clause 42: The method of any one of Clauses 39 to 41, wherein at least a portion of the at least one second diagonal brace and the second horizontal brace are disposed within the second post when rotated to be approximately parallel with the second post.

[0129] Clause 43: The method of any one of Clauses 39 to 42, wherein the at least one first diagonal brace and the first horizontal brace are fully disposed within an interior the first post when rotated to be approximately parallel with the first post.

[0130] Clause 44: The method of any one of Clauses 39 to 43, wherein the at least one second diagonal brace and the second horizontal brace are fully disposed within an interior the second post when rotated to be approximately parallel with the second post.

[0131] Clause 45: The method of any one of Clauses 39 to 44, wherein a bottom of the first post comprises a first baseplate and a bottom of the second post comprises a second baseplate; and wherein the method of packing further comprises rotating one of the first post or the second post prior to removably coupling the first post to the second post, such that the first baseplate of the first post is provided near a top of the second post when the first post and the second post are coupled together.

[0132] Clause 46: The method of any one of Clauses 39 to 45, further comprising removably coupling the first post and the second post such that the interior of the first post faces the interior of the second post.[01331 Clause 47: The method of any one of Clauses 39 to 45, further comprising removably coupling the first post and the second post such that the interior of the first post faces the exterior of the second post.

[0134] Clause 48: The method of any one of Clauses 39 to 47, further comprising removably coupling the first post and the second post such that the interior of the second post faces the exterior of the first post.

[0135] Clause 49: An upright frame of a pallet rack, comprising: a first post assembly, comprising: a first post; at least one first diagonal brace coupled to the first post; and a first horizontal brace coupled to the first post; and a second post assembly, comprising: a second post; at least one second diagonal brace coupled to the second post; and a second horizontal brace coupled to the second post.

[0136] Clause 50: The upright frame of Clause 49, wherein the first post and the second post are substantially c-shaped.

[0137] Clause 51 : The upright frame of Clause 49 or 50, wherein the first post and the second post each comprise an interior having a width greater than or approximately equal to twice the width of any one of the at least one first diagonal brace, the first horizontal brace, the at least one second diagonal brace, or the second horizontal brace.

[0138] Clause 52: The upright frame of any one of Clauses 49 to 51, further comprising a third horizontal brace for coupling to the first post and the second post.

[0139] Clause 53 : The upright frame of any one of Clauses 49 to 52, wherein the at least one first diagonal brace is coupled to the first post by one fastener provided through a through hole in the first post.

[0140] Clause 54: The upright frame of any one of Clauses 49 to 53, wherein the at least one first diagonal brace and the first horizontal brace are rotatably coupled to the first post, and wherein a majority length of the at least one first diagonal brace and the first horizontal brace are disposed within an interior of the first post when the at least one first diagonal brace and the first horizontal brace are rotated to be substantially parallel to the first post.

[0141] Clause 55: The upright frame of any one of Clauses 49 to 54, wherein the at least one second diagonal brace and the second horizontal brace are rotatably coupled the second post, and wherein a majority length of the at least one second diagonal brace and the second horizontal brace are disposed within an interior of the second post when the at least one second diagonal brace and the second horizontal brace are rotated to be substantially parallel to the second post.

[0142] Clause 56: The upright frame of any one of Clauses 49 to 55, wherein a first end of the second horizontal brace is coupled to the second post by a fastener provided through a corresponding through hole in the second post, a hole in the first end of the second horizontal brace, and a bushing, wherein the bushing is disposed within an interior of the second post.

[0143] Clause 57: The upright frame of any one of Clauses 49 to 56, wherein at least one of the at least one first diagonal brace, the at least one second diagonal brace, the first horizontal brace, and the second horizontal brace is telescoping.

[0144] Clause 58: The upright frame of any one of Clauses 49 to 56, wherein at least one of the at least one first diagonal brace, the at least one second diagonal brace, the first horizontal brace, and the second horizontal brace is foldable.

[0145] Clause 59: A method of packing an upright frame assembly, the upright frame assembly comprising: a post; and at least one brace coupled to the post; and the method of packing the upright frame assembly, comprising: rotating the at least one brace to be approximately parallel with the post; and temporarily securing the at least one brace to the post such that it remains approximately parallel to the post during transportation.

[0146] Clause 60: The method of Clause 59, wherein at least a portion of the at least one brace is disposed within the post when rotated to be approximately parallel with the post.

[0147] Clause 61 : The method of Clause 60, further comprising wrapping the post and the at least one brace.

[0148] The embodiments described above are cited by way of example, and the present invention is not limited by what has been particularly shown and described hereinabove. Rather, the scope of the invention includes both combinations and sub combinations of the various features described hereinabove, as well as variations and modifications thereof whichwould occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art.

Claims

CLAIMSWhat is claimed is:

1. A packaged upright frame of a pallet rack, comprising: a first post; a second post temporarily attached to the first post; and at least one brace.

2. The packaged upright frame of claim 1, wherein the first post is attached to the second post by at least one fastener.

3. The packaged upright frame of claim 2, wherein the at least one fastener comprises a bolt and a nut.

4. The packaged upright frame of claim 3, wherein the bolt passes through a first hole provided in a rear side of the first post and a second hole provided in a rear side of the second post.

5. The packaged upright frame of claim 4, wherein a plate is provided between the bolt and the rear side of the first post.

6. The packaged upright frame of any one of claims 1 to 5, wherein an open end of the first post faces towards an open end of the second post when the first post is attached to the second post.

7. The packaged upright frame of claim 6, wherein the at least one brace is provided in a space provided by an interior portion of the first post and / or an interior portion of the second post.

8. The packaged upright frame of claim 1, wherein the at least one brace is attached to the first post or the second post.

9. A method of packing an upright frame assembly, the upright frame assembly comprising: a first post; a second post, the first post and the second post comprising a substantially c-shaped cross-section; and at least one brace; and the method of packing the upright frame assembly, comprising: placing the at least one brace within an interior portion of the first post or the second post; and securing the first post to the second post.

10. The method of claim 9, wherein a first end of the at least one brace is attached to the first post or the second post.

11. The method of claim 9 or 10, wherein the first post is secured to the second post by at least one fastener.

12. The method of claim 11, wherein the at least one fastener comprises a bolt and a nut.

13. The method of claim 12, wherein the bolt passes through a first hole provided in a rear side of the first post and a second hole provided in a rear side of the second post.

14. The method of claim 13, wherein a plate is provided between the bolt and the rear side of the first post.

15. The method of claim 9, further comprising a step of facing an open end of the first post towards an open end of the second post prior to securing the first post to the second post.

16. The method of claim 15, wherein the at least one brace is provided in a space provided by the interior portion of the first post and / or an interior portion of the second post.

17. An upright frame assembly of a pallet rack, comprising: a post; and at least one brace coupled to the post.

18. The upright frame assembly of claim 17, wherein the post is substantially c-shaped.

19. The upright frame assembly of claim 17, wherein the post comprises an interior having a width greater than or approximately equal to twice the width of the at least one brace.

20. The upright frame assembly of claim 17, wherein the at least one brace is rotatably coupled to the post, and wherein a majority length of the at least one brace is disposed within an interior of the post when the at least one brace is rotated to be substantially parallel to the post.

21. The upright frame assembly of claim 17, wherein a first end of the at least one brace is coupled to the post by a fastener provided through a corresponding through hole in the post, a hole in the first end of the brace, and a bushing, wherein the bushing is disposed within an interior of the post.

22. The upright frame assembly of claim 17, wherein the at least one brace is telescoping.

23. The upright frame assembly of claim 17, wherein at least one of the at least one brace is foldable.

24. A method of assembling an upright frame, the upright frame comprising: a first post; at least one first diagonal brace coupled to the first post at a first end; at least one first horizontal brace coupled to the first post at a first end; a second post; at least one second diagonal brace coupled to the second post at a first end; at least one second horizontal brace coupled to the second post at a first end; the method comprising: rotating a second end the at least one first diagonal brace away from first post; coupling the second end of the at least one first diagonal brace to the second post; rotating a second end of the first horizontal brace away from the first post; coupling the second end of the first horizontal brace to the second post; rotating a second end of at least one second diagonal brace away from the second post; coupling the second end of the at least one second diagonal brace to the first post; and rotating a second end of the at least one second horizontal brace away from the second post; and coupling the second end of the at least one second horizontal brace to the first post.

25. The method of claim 24, further comprising coupling a first end of a third horizontal brace to the first post and coupling a second end of the third horizontal brace to the second post.

26. The method of claim 25, wherein coupling the third horizontal brace to the first post comprises providing fastener through a hole provided at the first end of the third horizontal brace, a third corresponding hole of the first post, and a bushing; and fastening the first end of the third horizontal brace to the first post.

27. The method of claim 25, wherein the second end of one of the at least one second diagonal brace abuts a first end of the first horizontal brace.

28. The method of claim 25, wherein the second end of one of the at least one first diagonal brace abuts a first end of the second diagonal brace.

29. A method of packing an upright frame, the upright frame comprising: a first post; at least one first diagonal brace coupled to the first post at a first end; at least one first horizontal brace coupled to the first post at a first end; a second post; at least one second diagonal brace coupled to the second post at a first end; at least one second horizontal brace coupled to the second post at a first end; the method comprising: rotating the at least one first diagonal brace and the first horizontal brace to be approximately parallel with the first post; and rotating the least one second diagonal brace and the second horizontal brace to be approximately parallel with the second post.

30. The method of claim 29, wherein at least a portion of the at least one first diagonal brace and the first horizontal brace are disposed within the first post when rotated to be approximately parallel with the first post.

31. The method of claim 29, wherein the at least one first diagonal brace is coupled to the first post by one fastener provided through a corresponding through hole provided in the first post.

32. The method of claim 29, wherein at least a portion of the at least one second diagonal brace and the second horizontal brace are disposed within the second post when rotated to be approximately parallel with the second post.

33. The method of claim 29, wherein the at least one first diagonal brace and the first horizontal fully disposed within an interior the first post when rotated to be approximately parallel with the first post.

34. The method of claim 29, wherein the at least one second diagonal brace and the second horizontal brace are fully disposed within an interior the second post when rotated to be approximately parallel with the second post.

35. The method of claim 29, wherein a bottom of the first post comprises a plate and a bottom of the second post comprises a second baseplate; and wherein the method of packing further comprises rotating one of the first post or the second post prior to removably coupling the first post to the second post, such that the first baseplate of the first post is provided near a top of the second post when the first post and the second post are coupled together.

36. The method of claim 29, further comprising removably coupling the first post and the second post such that the interior of the first post faces the interior of the second post.

37. The method of claim 29, further comprising removably coupling the first post and the second post such that the interior of the first post faces the exterior of the second post.

38. The method of claim 29, further comprising removably coupling the first post and the second post such that the interior of the second post faces the exterior of the first post.

39. A method of preassembling an upright frame of a pallet rack, comprising: preassembling a first post assembly, comprising: coupling at least one first diagonal brace to a first post; coupling a first horizontal brace to the first post; and preassembling a second post assembly, comprising:coupling at least one second diagonal brace to a second post; and coupling a second horizontal brace to the second post.

40. The method of claim 39, wherein the at least one first diagonal brace is coupled to the first post by one fastener provided through a through hole provided in the first post, wherein the at least one first diagonal brace is pivotably rotatable relative to the first post.

41. The method of claim 39, wherein coupling the at least one first diagonal brace to the first post comprises: providing a fastener through a hole provided at a first end of each of the at least one first diagonal brace and a first corresponding hole of the first post; and fastening the first end of the at least one first diagonal brace to the first post.

42. The method of claim 39 wherein coupling the first horizontal brace to the first post comprises providing a fastener through a hole provided at a first end of the first horizontal brace, a second corresponding hole of the first post, and a bushing; and fastening the first end of the first horizontal brace to the first post, wherein the first horizontal brace is pivotably rotatable relative to the first post.

43. The method of claim 39, wherein coupling the at least one second diagonal brace to the second post comprises: providing a fastener through a hole provided at a first end of the at least one second diagonal braces and a first corresponding hole of the second post; and fastening the first end of the at least one second diagonal braces to the second post, wherein the at least one second diagonal brace is pivotably rotatable relative to the second post.

44. The method of claim 39, wherein coupling the second horizontal brace to the second post comprises providing a fastener through a hole provided at a first end of the second horizontal brace, a second corresponding hole of the second post, and a bushing; and fastening the first end of the second horizontal brace to the second post, wherein the second horizontal brace is pivotably rotatable relative to the second post.3145. The method of claim 44, further comprising a step of indicating a corresponding hole on the first post for fastening a second end of the second horizontal brace.

46. The method of claim 45, wherein indicating the corresponding hole on the first post for fastening the second end of the second horizontal brace comprises providing a fastener in the corresponding hole.

47. The method of claim 45, wherein indicating the corresponding hole on the first post for fastening the second end of the second horizontal brace comprises providing visual indication on the first post at the corresponding hole.

48. The method of claim 39, further comprising fastening a first baseplate to a bottom of the first post and fastening a second baseplate to a bottom of the second post.

49. An upright frame of a pallet rack, comprising: a first post assembly, comprising: a first post; at least one first diagonal brace coupled to the first post; and a first horizontal brace coupled to the first post; and a second post assembly, comprising: a second post; at least one second diagonal brace coupled to the second post; and a second horizontal brace coupled to the second post.

50. The upright frame of claim 49, wherein the first post and the second post are substantially c-shaped.

51. The upright frame of claim 49, wherein the first post and the second post each comprise an interior having a width greater than or approximately equal to twice the widthof any one of the at least one first diagonal brace, the first horizontal brace, the at least one second diagonal brace, or the second horizontal brace.

52. The upright frame of claim 49, further comprising a third horizontal brace for coupling to the first post and the second post.

53. The upright frame of claim 49, wherein the at least one first diagonal brace is coupled to the first post by one fastener provided through a through hole in the first post.

54. The upright frame of claim 49, wherein the at least one first diagonal brace and the first horizontal brace are rotatably coupled to the first post, and wherein a majority length of the at least one first diagonal brace and the first horizontal brace are disposed within an interior of the first post when the at least one first diagonal brace and the first horizontal brace are rotated to be substantially parallel to the first post.

55. The upright frame of claim 49, wherein the at least one second diagonal brace and the second horizontal brace are rotatably coupled the second post, and wherein a majority length of the at least one second diagonal brace and the second horizontal brace are disposed within an interior of the second post when the at least one second diagonal brace and the second horizontal brace are rotated to be substantially parallel to the second post.

56. The upright frame of any one of claims 49 to 55, wherein a first end of the second horizontal brace is coupled to the second post by a fastener provided through a corresponding through hole in the second post, a hole in the first end of the second horizontal brace, and a bushing, wherein the bushing is disposed within an interior of the second post.

57. The upright frame of claim 56, wherein at least one of the at least one first diagonal brace, the at least one second diagonal brace, the first horizontal brace, and the second horizontal brace is telescoping.

58. The upright frame of claim 49, wherein at least one of the at least one first diagonal brace, the at least one second diagonal brace, the first horizontal brace, and the second horizontal brace is foldable.

59. A method of packing an upright frame assembly, the upright frame assembly comprising: a post; and at least one brace coupled to the post; and the method of packing the upright frame assembly, comprising: rotating the at least one brace to be approximately parallel with the post; and temporarily securing the at least one brace to the post such that it remains approximately parallel to the post during transportation.

60. The method of claim 59, wherein at least a portion of the at least one brace is disposed within the post when rotated to be approximately parallel with the post.

61. The method of claim 60, further comprising wrapping the post and the at least one brace.

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