Composite aisle frame system

Abstract

A composite aisle frame system includes a pair of trusses arranged in parallel, each truss comprising vertical bracing members defining slots therethrough. Cross-arms extend through aligned slots in both trusses, coupling the trusses together. Struts disposed on opposite ends of each cross-arm present profiles larger than the slots to retain the cross-arms within the slots. A peripheral surface between each slot and an outer edge of the vertical bracing member provides a sealing land for containment panels that separate airflows within the system. At least a portion of the system comprises a composite material such as fiber reinforced polymer, reducing weight compared to all-metal constructions. A lower unit comprising columns supports the trusses. The system is configured to limit dynamic deflection under seismic loading, maintaining clearance from adjacent equipment.

Description

COMPOSITE AISLE FRAME SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Application No. 63 / 755,434, titled Composite Aisle Frame System, filed February 7, 2025, which is hereby incorporated by reference in its entirety.BACKGROUND

[0002] Aisle frames are structural components used in data centers to support equipment racks, cable management systems, and utilities such as power distribution and network cabling. These frames typically comprise vertical columns and horizontal beams arranged to define aisles between rows of server racks. In addition to organizing equipment, aisle frames facilitate airflow management for cooling by providing structure for containment systems that separate hot exhaust air from cool supply air.

[0003] Data centers in seismically active regions face particular challenges. During earthquakes, aisle frames may be subjected to significant lateral forces and ground accelerations that can cause deformation, displacement, or structural failure. Such damage poses risks to the expensive and sensitive equipment supported by the frames, potentially resulting in equipment failure, data loss, and operational downtime. Structural failure during a seismic event also presents safety hazards for personnel.

[0004] Traditional aisle frames constructed entirely from steel or aluminum can be heavy, which increases floor loading requirements and may limit installation options on upper building stories or raised floor systems with load restrictions. The weight of conventional frames also increases shipping and handling costs and may complicate installation in space-constrained environments.

[0005] There is an ongoing need for aisle frame designs that provide sufficient strength and stiffness to resist seismic forces while reducing weight compared to conventional all-metal constructions. Such designs should maintain the functional requirements of aisle frames, includingequipment support, utility routing, and airflow containment, while allowing for efficient assembly, disassembly, and reconfiguration as data center needs evolve.BRIEF DESCRIPTION OF FIGURES

[0006] While the specification concludes with claims which particularly point out and distinctly claim the invention, it is believed the present invention will be better understood from the following description of certain examples taken in conjunction with the accompanying drawings, in which like reference numerals identify the same elements and in which:

[0007] FIG. 1 depicts a perspective view of a pair of trusses of a composite aisle frame system, with each truss having a series of vertical bracing members defining slots therethrough;

[0008] FIG. 2 depicts a perspective view of the two trusses of FIG. 1 connected with a pair of upper beams and a pair of lower beams;

[0009] FIG. 3 depicts a perspective view of a plurality of cross-arms being extended through corresponding slots of FIG. 1, with a strut disposed on a first end of each cross-arm and a second end being free from a strut;

[0010] FIG. 4 depicts a perspective view of the cross-arms of FIG. 3 extended through the slots and receiving a strut on the second end;

[0011] FIG. 4A depicts a cross-sectional view taken along line 4A-4A of FIG. 4;

[0012] FIG. 5 depicts a perspective view of an upper unit comprising a pair of trusses with cross-arms extended therethrough and struts on both ends, with a lower unit connected to raise the upper unit off a surface;

[0013] FIG. 6 depicts a perspective view of a mechanism for disassembling and reassembling the upper unit and lower unit of FIG. 5;

[0014] FIG. 7 depicts a perspective view of the upper unit and lower unit of FIG. 5 in a disassembled state for flat packing into a shipping configuration;

[0015] FIG. 8 depicts a perspective view of a truss with cross-arms shown in cross section and a peripheral surface sized to receive a containment panel;

[0016] FIG. 9 depicts a perspective view of a composite aisle frame system with adjustable arms extending from adjustment mechanisms connected to vertical bracing members and disposed on a raised floor pedestal system; and

[0017] FIG. 10 depicts a perspective view of a composite aisle frame system disposed proximate a plurality of racks.

[0018] The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.DETAILED DESCRIPTION

[0019] The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

[0020] It will be appreciated that any one or more of the teachings, expressions, versions, examples, etc. described herein may be combined with any one or more of the other teachings, expressions, versions, examples, etc. that are described herein. The following-described teachings, expressions, versions, examples, etc. should therefore not be viewed in isolation relative to each other. Various suitable ways in which the teachings herein may be combined will be readily apparent to those of ordinary skill in the art in view of the teachings herein. Such modifications and variations are intended to be included within the scope of the claims.I System Elements

[0021] The present disclosure relates to a composite aisle frame system (1), alternatively referred to as "system (1)," designed for use with server racks (60) (FIG. 10) in data centers and similar technology environments. System (1) is configured to withstand seismic events without buckling or excessive deflection while providing a lightweight alternative to traditional steel aisle frames. By incorporating composite materials such as fiber reinforced polymer (FRP) in various structural elements, system (1) may reduce overall weight by up to 50% compared to all-steel designs while maintaining or exceeding the structural performance of conventional frames.

[0022] As shown in FIGS. 1-10, system (1) incorporates structural elements arranged to withstand seismic forces while maintaining aisle frame functionality and allowing for efficient assembly and disassembly. The selection of composite materials for particular elements of system (1) may be based on the structural requirements, weight considerations, seismic demands, corrosion resistance needs, and cost targets of a given installation. In some implementations, system (1) may employ a hybrid construction in which certain elements are formed from composite materials while other elements are formed from metallic materials such as steel or aluminum, thereby optimizing the balance between weight reduction, structural performance, and cost.

[0023] A. Trusses, Slots, and Bridging Members

[0024] As shown in FIG. 1, system (1) includes a pair of trusses (3) arranged parallel to each other and extending vertically. Each truss (3) comprises a framework of interconnected structural members, including a plurality of vertical bracing members (5) positioned at intervals along the length of each truss (3). Vertical bracing members (5) define slots (7) therethrough, which may be located in the general center of vertical bracing members (5) and extend horizontally to maintain stability and provide even distribution of weight across system (1). Trusses (3) may include diagonal beams between vertical bracing members (5) for additional reinforcement, and define openings (19) therethrough and between the various structural members. In some implementations, trusses (3) or portions thereof may be formed from a composite material such as FRP to reduce weight while maintaining structural integrity and providing enhanced corrosion resistance in humid data center environments. In other implementations, vertical bracing members (5) may be formed from steel or aluminum to provide localized strength and stiffness at connection pointswhere slots (7) receive cross-arms (13), while other truss components such as diagonal beams and horizontal rails are formed from composite materials to reduce overall weight.

[0025] The selection of materials for different truss components may be optimized based on the load paths, stress concentrations, and connection requirements at each location within truss (3). In some implementations, slots (7) in the first truss and slots (7) in the second truss are aligned along a common horizontal axis to facilitate insertion of cross-arms (13) through both slots (7) in a single linear motion, simplifying installation and ensuring proper alignment. Vertical bracing members (5) of each truss (3) may be positioned at matching intervals to provide multiple aligned slot pairs, and the alignment of slots (7) between trusses (3) may be maintained by upper beams (9) and lower beams (11), which hold trusses (3) in a fixed spatial relationship during and after installation of cross-arms (13).

[0026] Slots (7) may be defined at varying vertical positions along vertical bracing members (5) to accommodate different cross-arm (13) heights, with vertical spacing that is uniform or varies based on the intended utility support configuration. Slots (7) may be elongated in the vertical direction to permit adjustment during installation, allowing installers to fine-tune the elevation of cross-arms (13) to match site-specific requirements, or multiple discrete slots (7) may be defined at predetermined intervals to provide fixed mounting positions for cross-arms (13). The shape of slots (7) may be rectangular, oval, or other configurations selected to accommodate the cross-sectional profile of cross-arms (13) while providing the desired degree of adjustability or fixed positioning, and may include radiused corners or chamfered edges to reduce stress concentrations and facilitate insertion of cross-arms (13).

[0027] FIG. 2 depicts trusses (3) connected by multiple bridging members (12) to form a boxlike structure that provides three-dimensional stability and rigidity. Bridging members (12) are structural elements or subassemblies that extend between trusses (3) to couple, stabilize, and space trusses (3), and optionally to carry or route utilities such as electrical conductors, cable trays, bus duct, cooling pipes, and fluid conduits. Bridging members (12) may comprise a single bar, tube, or beam, or a multi-member frame including parallel cross-members and one or more diagonal members arranged in a triangulated configuration for enhanced stiffness. Utilities may rest upon bridging members (12) or pass through portions thereof, and ends of bridging members (12) maybe secured to trusses (3) by bolts, pins, clips, or other fasteners that facilitate field assembly and permit future reconfiguration.

[0028] Bridging members (12) may be formed of steel, aluminum, a composite material such as FRP, or combinations thereof, with the material selection based on the span length, anticipated loads, and weight targets for each bridging member location. In some implementations, bridging members (12) that span longer distances or support heavier utility loads may be formed from FRP to achieve favorable stiffness-to-weight ratios, while bridging members (12) at high-stress connection points or locations requiring frequent reconfiguration may be formed from metallic materials for enhanced durability and fastener compatibility.

[0029] The bridging members (12) of FIG. 2 include a pair of upper beams (9) and a pair of lower beams (11) extending between trusses (3) to maintain relative positioning and spacing throughout the length of system (1). Upper beams (9) and lower beams (11) may be formed from FRP, steel, aluminum, or combinations thereof depending on the structural requirements, weight targets, and cost considerations for a particular installation. In some implementations, upper beams (9) may be formed from FRP to reduce weight at the top of system (1), while lower beams (11) may be formed from steel to provide a robust connection interface with columns (21) of lower unit (25). The arrangement of trusses (3), upper beams (9), lower beams (11), vertical bracing members (5), and slots (7) contributes to the overall structural integrity of system (1) and enables system (1) to resist lateral forces during seismic events.

[0030] B. Cross-Arms and Struts

[0031] As shown in FIG. 3, slots (7) are sized and configured to receive cross-arms (13), another form of bridging members (12) that provides both structural coupling between trusses (3) and utility support. Cross-arms (13) extend through aligned slots (7) in both trusses (3), passing entirely from one side of system (1) to the other and binding trusses (3) together into a unified structural assembly. Cross-arms (13) are particularly well-suited for fabrication from composite materials such as FRP because they are elongated structural elements requiring high stiffness and low weight to span the distance between trusses (3) while supporting utilities without excessive deflection.

[0032] Tn some implementations, cross-arms (13) are formed by pultrusion, a continuous manufacturing process that produces components having a constant cross-sectional profde with fibers oriented primarily along the length of the component for maximum longitudinal stiffness. The pultrusion process is advantageous for fabricating cross-arms (13) because it produces consistent, high-quality profiles at relatively low cost and enables the use of continuous fiber reinforcement for enhanced mechanical properties. The use of FRP for cross-arms (13) may significantly reduce the weight of upper unit (23) while providing sufficient strength and stiffness to support utilities and resist seismic forces, and may also provide enhanced corrosion resistance compared to steel cross-arms in humid or corrosive data center environments.

[0033] As depicted in FIG. 3, cross-arms (13) may initially include a strut (17) on one end while omitting a strut (17) on the other end to enable insertion through slots (7) from one side of system (1). FIGS. 4 and 4A illustrate cross-arms (13) fully extended through each truss (3), binding trusses (3) together and stabilizing overall system (1) against lateral movement. Cross-arms (13) are sized and configured to protrude beyond the outer edges of trusses (3) to create shelf-like structures for supporting computer systems, network equipment, and various utilities, and once cross-arms (13) are extended entirely through trusses (3), a strut (17) is disposed on the outer end of each cross-arm (13) to complete the installation. Struts (17) secure cross-arms (13) within slots (7) because the larger profile of struts (17) compared to slots (7) prevents lateral movement of cross-arms (13) out of slots (7) in either direction.

[0034] A pair of struts (17) disposed on opposite ends of a single cross-arm (13) cooperates to secure cross-arm (13) within the corresponding slots (7) of vertical bracing members (5) and prevent lateral displacement in either direction along the longitudinal axis of cross-arm (13). In some cases, the pair of struts (17) may be configured to apply a clamping force against the outer faces of vertical bracing members (5), thereby further stabilizing cross-arm (13) within slots (7) and enhancing the rigidity of the connection. The pair of struts (17) provides symmetric utility support on both sides of system (1), enabling balanced loading of cross-arm (13) and reducing the risk of uneven stress distribution. Struts (17) help distribute the weight of supported utilities evenly across system (1) and may accommodate different utility types such as cable trays, piping, electrical conduits, and cooling lines. Cross-arms (13) may be designed to support additional utility weight inside or between the two trusses (3), including components such as piping, lighting,wiring, and cable management systems, and by utilizing cross-arms (13) for this purpose, system (1) may efficiently integrate necessary infrastructure while maintaining structural integrity.

[0035] Struts (17) may be configured in various forms depending on utility support requirements, load capacity needs, and installation preferences. In some implementations, struts (17) comprise a flat plate oriented perpendicular to the longitudinal axis of cross-arm (13), providing a simple withdrawal stop and a planar surface for utility attachment using clamps, straps, or fasteners. In other implementations, struts (17) comprise an L-shaped bracket having a first leg secured to cross-arm (13) and a second leg extending outwardly to provide an enlarged utility support surface capable of supporting cable trays, conduit runs, or equipment mounting brackets. In still other implementations, struts (17) comprise a T-shaped bracket providing both a withdrawal stop function and utility support surfaces extending in two opposing directions from cross-arm (13), enabling utilities to be supported on both sides of the strut.

[0036] Struts (17) may be formed from steel, aluminum, or composite materials such as FRP, with the material selection based on the anticipated loads, environmental conditions, and weight targets for a particular installation. In implementations where struts (17) are formed from FRP, struts (17) may be integrally formed with cross-arms (13) as a single pultruded or molded component, simplifying assembly, eliminating the need for mechanical attachment, and providing a seamless load path between cross-arm (13) and strut (17). Integrally formed struts (17) may also reduce the total part count of system (1) and eliminate potential failure points at fastener locations. In other implementations, struts (17) may be separately formed and attached to cross-arms (13) using bolts, pins, welding, adhesive bonding, or other fastening methods selected based on the materials of struts (17) and cross-arms (13). The attachment between struts (17) and cross-arms (13) may be permanent for maximum structural integrity, or may be releasable to permit removal of cross-arms (13) from slots (7) during reconfiguration, maintenance, or relocation of system (1).

[0037] C. Upper Unit and Lower Unit

[0038] As shown in FIG. 5, the elements described above, including trusses (3), cross-arms (13), struts (17), upper beams (9), lower beams (11), crossbeams (20), and diagonal members (22), belong to an upper unit (23). System (1) may include a lower unit (25) comprising a plurality of columns (21) configured to elevate upper unit (23) off the ground or floor surface, positioningstruts (17) and cross-arms (13) at the desired vertical height for utility support and equipment access. Columns (21) may be positioned at the base of trusses (3), and create space beneath trusses (3) for easier access to the underside of the structure for maintenance, inspection, or installation of additional components.

[0039] The elevation provided by columns (21) may also help protect the main components of system (1) from potential ground-level hazards, moisture, flooding, or cleaning activities. The connection between trusses (3) and columns (21) is designed to balance strength, stiffness, and assembly efficiency, and may be achieved using bolts, pins, or other fasteners optimized for the expected loads and seismic conditions. The specific configuration of fasteners may be selected based on the anticipated loads, with larger diameter bolts or multiple fastener patterns used in higher seismic environments. Plates, gussets, or other structures may be used to help secure columns (21) to trusses (3) and distribute connection forces over a larger area.

[0040] The design and material selection for columns (21) may vary depending on seismic requirements, weight considerations, corrosion resistance needs, and cost targets for a particular installation. For lower seismic areas with ground accelerations up to about 0.2 G's, columns (21) may be constructed from composite materials such as FRP, potentially further reducing the overall weight of system (1), simplifying installation, and providing enhanced corrosion resistance. Composite columns (21) may be attached directly to the floor using base plates and anchor bolts, providing a lightweight yet stable foundation for system (1).

[0041] In moderate to high seismic environments with ground accelerations up to about 0.6 G's or higher, columns (21) may be formed from steel or aluminum to provide increased strength, stiffness, and ductility for energy absorption during seismic events. Steel columns (21) may be employed in high seismic environments where maximum strength and stiffness are required to resist lateral forces and maintain structural integrity, while aluminum columns (21) may be employed where reduced weight is prioritized, such as installations on upper building stories with floor loading restrictions or on raised floor systems with limited load capacity. The selection between steel and aluminum for columns (21) may also be influenced by factors such as corrosion resistance requirements, cost considerations, and compatibility with other system components and fasteners.

[0042] Columns (21) may include a combination of materials to optimize performance, such as steel base plates for robust floor attachment combined with aluminum or composite column shafts for reduced weight, or steel connection plates at the top of columns (21) for secure attachment to trusses (3) combined with composite column shafts for weight reduction along the length. Columns (21) may define various cross-sectional shapes selected to provide the desired strength and stiffness characteristics, including hollow rectangular or square cross-sections that provide favorable resistance to bending in multiple directions, circular or tubular cross-sections that provide uniform strength in all directions, or I-beam cross-sections that provide efficient use of material for bending resistance.

[0043] The base of each column (21) may include a base plate configured to distribute loads over a larger area of the floor surface, reducing localized floor loading and providing a stable foundation. The base plate may include mounting holes for securing column (21) to the floor using anchor bolts, expansion anchors, or other fasteners appropriate for the floor construction. In implementations where system (1) is installed on a raised floor pedestal system (37), the base plate may be configured to interface with one or more pedestals (39) or with an interface plate spanning multiple pedestals (39) to distribute reaction forces across multiple support points. Columns (21) may also include gussets, stiffeners, or other reinforcing elements at locations where trusses (3) connect to columns (21), to facilitate load transfer, enhance the rigidity of the connection, and reduce stress concentrations at the joint.

[0044] Once cross-arms (13) are in place and extending between trusses (3) as desired, additional mounting members such as crossbeams (20) and diagonal members (22) may be secured to a portion of upper unit (23) to further enhance structural integrity and provide additional mounting surfaces. Crossbeams (20) extend between two vertical bracing members (5) within a single truss (3), reinforcing trusses (3) by holding vertical bracing members (5) to one another internally and increasing the in-plane stiffness of trusses (3). Crossbeams (20) further create a backing structure to rest sealing elements against when disposed within opening (19), providing support for containment panels (43) as described in greater detail below. Diagonal members (22) extend between two bridging members (12) such as cross-arms (13) to hold cross-arms (13) to one another internally between trusses (3), creating a triangulated configuration that resists racking and enhances the overall stability of system (1). Crossbeams (20) and diagonal members (22) may beformed from steel, aluminum, or composite materials such as FRP depending on the structural requirements, weight targets, and cost considerations for a particular installation. In some implementations, crossbeams (20) may be formed from steel or aluminum to provide robust attachment points for containment panels (43) and associated hardware, while diagonal members (22) may be formed from FRP to reduce weight in locations where panel attachment is not required.

[0045] D. Assembly and Disassembly

[0046] As shown in FIG. 6, system (1) is designed for efficient assembly and disassembly, facilitating installation, transportation, and future reconfiguration. The use of composite materials in upper unit (23) reduces the weight of individual components, making them easier to handle, lift, and position during assembly without requiring heavy lifting equipment in many cases. The reduced component weight may also reduce the risk of injury to installation personnel and enable faster installation with smaller crews. Assembly may begin with placement of columns (21) at predetermined locations corresponding to the desired rack spacing pattern (61) and aligned with the underlying floor structure or raised floor pedestal system (37). Trusses (3) are then set vertically and spaced apart at the desired aisle width, and upper beams (9) and lower beams (11) are connected between trusses (3) to form a box-like structure that maintains the relative positioning and spacing of trusses (3). This box-like structure is then attached to columns (21) at various points along trusses (3) if additional height is required to position cross-arms (13) and struts (17) at the desired elevation. Cross-arms (13) are inserted through slots (7) in vertical bracing members (5) of trusses (3), extending from one side of system (1) to the other, and struts (17) are attached to the ends of each cross-arm (13) to provide utility support and secure cross-arms (13) within slots (7).

[0047] System (1) allows a modular approach to assembly in which sections of system (1) may be pre-assembled at a manufacturing facility or staging area before being transported to the final installation site, potentially reducing on-site assembly time, improving quality control, and minimizing disruption to ongoing data center operations. For example, trusses (3) may be preassembled with crossbeams (20), diagonal beams, bolts, plates, and other internal components before shipping or transport, so that trusses (3) arrive at the installation site as completesubassemblies ready for erection. Trusses (3) may be assembled in a horizontal orientation on the floor and then tilted up into a vertical position before being connected by bridging members (12), which may be advantageous in installations with limited overhead clearance. In other implementations, trusses (3) may be assembled in place in a vertical orientation, with bridging members (12) installed progressively from the bottom up or from the top down depending on access requirements and installation preferences. Struts (17) may be pre-attached to one end of cross-arms (13) before insertion through slots (7), facilitating handling and alignment during installation, while the subsequent attachment of struts (17) to the opposite end secures cross-arms (13) within slots (7) and completes the installation. The modular nature of the components permits partial assembly at a manufacturing facility with final assembly completed at the installation site, thereby reducing on-site labor requirements, installation time, and the potential for assembly errors.

[0048] FIG. 7 depicts system (1) in a fully disassembled state suitable for shipping or storage. The flat-packing capability of system (1) results in a compact profile that facilitates efficient shipping by enabling more systems to be transported per shipment, reducing transportation costs and logistical challenges associated with oversized freight. The reduced weight of composite components further reduces shipping costs compared to all-steel systems and may enable shipment by standard freight carriers rather than specialized heavy equipment transporters. The compact disassembled configuration is also beneficial for storage in space-limited environments such as warehouses, staging areas, or on-site storage rooms where floor space is at a premium. The modular design of system (1) enables quick disassembly for relocation or maintenance, allowing system (1) to be moved to a new location within a data center or to an entirely different facility as operational needs change. The modular design also allows replacement or upgrade of individual parts without requiring replacement of the entire system, enabling targeted repairs, component upgrades, or capacity expansions as needed. This assembly and disassembly capability contributes to the versatility of system (1), allowing for temporary installations during data center construction or renovation, or enabling reconfiguration of system (1) as rack layouts, utility routing, or containment requirements change over time in response to evolving data center needs.

[0049] E. Peripheral Surface and Containment

[0050] As shown in FIG. 8, system (1 ) defines a peripheral surface (18) disposed as the surface between where bridging members (12) connect to vertical bracing members (5) and the outer edge of that vertical bracing member (5). As specifically shown in FIG. 8, peripheral surface (18) exists as the space between where slots (7) are disposed on vertical bracing member (5) and the outer edge of that vertical bracing member (5), and this surface continues around the non-vertical bracing member area of trusses (3) and onto the next vertical bracing member (5), creating a substantially continuous sealing land around the perimeter of each opening (19). The width of cross-arm (13) may be selected so as to preserve a peripheral surface (18) sufficient for containment sealing as described in more detail below. In some versions, cross-arm (13) width is no greater than about one-third of a corresponding width of vertical bracing member (5), thereby maintaining a robust sealing area on both sides of the slot (7) while still enabling structural coupling through the slot. Thus, in general, approximately one-third of the width of each vertical bracing member (5) is provided for the connecting location and profile of where bridging members (12) connect to vertical bracing members (5), with approximately one-third of the width being for a first peripheral surface (18) on one side of the connecting area and approximately one-third of the width being for a second peripheral surface (18) on the other side of the connecting area.

[0051] A containment panel (43) may be applied to peripheral surface (18) and crossbeams (20) to create a substantially hermetic barrier separating incoming cool air from hot exhaust air and sealing a particular opening (19). Containment panels (43) may be formed from twin wall acrylic, glass, polycarbonate, composite laminates, or other suitable transparent or opaque materials, and may be framed by a panel frame (45) that provides structural support and facilitates attachment to peripheral surface (18). Panel frames (45) may be formed from aluminum, steel, or composite materials depending on the weight, strength, and cost requirements for a particular installation.

[0052] Containment panels (43) may be affixed to peripheral surface (18) and crossbeams (20) using mechanical fasteners (47) such as screws, bolts, or clips, and / or an adhesive system such as double-sided tape, structural adhesive, or sealant. Mechanical fastening facilitates future panel modification, such as cutting service apertures for cables or pipes, and enables panel removal for maintenance access, while adhesive bonding can reduce localized stress concentrations at fastener locations and provide enhanced sealing performance.

[0053] Containment panels (43) are positioned on an inside surface of truss (3), meaning the surface of truss (3) that faces the interior of the aisle defined between the pair of trusses (3). The inside surface is opposite to the outside surface of truss (3), which faces outwardly toward adjacent server racks (60) or other equipment external to system (1). By mounting containment panel (43) on the inside surface of truss (3), containment panel (43) is recessed within the structural depth of truss (3) rather than protruding beyond the outer edges of truss (3). This inside-surface mounting positions containment panel (43) against peripheral surface (18) and crossbeams (20), which serve as backing members disposed within the plane of truss (3). The inside-surface positioning provides several advantages: it maintains clearance between system (1) and adjacent equipment such as server racks (60), it protects containment panel (43) from accidental contact or damage during equipment installation and maintenance activities, and it enables peripheral surface (18) and crossbeams (20) to resist air pressure loads acting on containment panel (43) by providing a backing structure against which containment panel (43) bears when subjected to pressure differentials.

[0054] Peripheral surface (18) and crossbeams (20) stabilize containment panels (43) against air pressure differentials between the contained aisle and the surrounding environment, and prevent panel deflection or "ballooning" caused by airflow pressure. Crossbeams (20) serve as backing members for containment panels (43), providing a surface against which containment panels (43) may be secured and supported at intermediate locations within opening (19). In some implementations, crossbeams (20) may be positioned to span across opening (19) at locations where containment panel (43) requires intermediate support to resist deflection caused by air pressure differentials, and the combination of peripheral surface (18) and crossbeams (20) creates a substantially continuous mounting surface around the perimeter and across the interior of opening (19) that facilitates secure attachment of containment panel (43) and enhances the integrity of the air seal. Crossbeams (20) may be spaced at intervals selected to limit the unsupported span of containment panel (43), thereby reducing the risk of panel deflection, vibration, or failure under pressure loading, and may provide attachment points for panel frames (45), gaskets, or other sealing elements that contribute to the hermetic barrier formed by containment panel (43).

[0055] Containment panels (43) may be employed in hot aisle or cold aisle containment configurations commonly used in data center environments to improve cooling efficiency andreduce energy consumption. In a cold aisle containment configuration, containment panels (43) may be positioned to enclose an aisle receiving conditioned air from an underfloor plenum or overhead supply, thereby directing the cool air stream toward server rack inlets and preventing the cool air from mixing with hot exhaust air before reaching the equipment. In a hot aisle containment configuration, containment panels (43) may be positioned to enclose an aisle receiving heated exhaust air discharged from server rack outlets, thereby directing the hot air stream toward return vents or cooling units and preventing the hot air from recirculating to equipment inlets.

[0056] The positioning of containment panel (43) against peripheral surface (18) and crossbeams (20) creates a boundary that prevents mixing of the cool supply air with the hot exhaust air, which may significantly improve cooling efficiency, reduce cooling energy consumption, and enable higher equipment densities within the data center. In some implementations, the seal formed between containment panel (43) and peripheral surface (18) may be configured to accommodate pressure differentials between the contained aisle and the surrounding environment using flexible gaskets, brush seals, or compliant sealing elements that maintain the seal while permitting minor structural movements.

[0057] Where cross-arms (13) are present within opening (19), the above-noted one-third width selection may be employed to maintain sufficient peripheral surface (18) for sealing around the cross-arm (13), and optional edge gaskets or semi-rigid seal carriers may conform around local protrusions to maintain seal integrity. A door panel may be disposed within a particular opening (19) to provide access through system (1) while maintaining containment when closed. The door panel may be hinged to peripheral surface (18), vertical bracing members (5), crossbeams (20), or other structural elements of truss (3), permitting the door panel to swing open and closed about a vertical or horizontal axis for personnel or equipment access.

[0058] In other implementations, the door panel may be slidably mounted to permit the door panel to translate laterally or vertically between open and closed positions, which may be advantageous in installations where swing clearance is limited. When closed, the door panel may seal against peripheral surface (18) and / or crossbeams (20) using gaskets, brush seals, magnetic seals, or other sealing elements to maintain separation between hot and cold air streams, and may include a latch, magnetic closure, or other securing mechanism to maintain the closed positionduring normal operation. In some cases, the door panel may be configured to open automatically in response to a pressure differential exceeding a threshold value, thereby serving as a pressure relief mechanism that prevents excessive pressure buildup within the contained aisle during cooling system transients or failure events. The door panel may be formed from the same materials as containment panels (43), such as twin wall acrylic, glass, polycarbonate, or composite laminates, and may be framed by a door frame similar to panel frame (45) for structural support and attachment of hinges, latches, and sealing elements.

[0059] F. Span Assemblies and Adjustable Arms

[0060] As shown in FIG. 9, bridging members (12) may include span assemblies (35) that span between trusses (3) to stabilize system (1) and carry or route utilities. Span assembly (35) is a cross-truss sub-assembly that provides both structural coupling between trusses (3) and a platform for utility support, and may be used in addition to or as an alternative to cross-arms (13) depending on the structural and utility support requirements of a particular installation. In some versions, span assembly (35) includes a pair of generally parallel cross-members (36), individually referred to as a top cross-member (36A) and a bottom cross-member (36B), that are spaced apart vertically to create a moment-resisting frame configuration.

[0061] As shown in FIG. 10, utilities such as electrical wiring, cable trays, bus duct, cooling pipes, and fluid conduits may rest on top cross-member (36A) and / or extend through span assembly (35) at selected locations between cross-members (36A, 36B). Span assembly (35) may further include one or more diagonal members (40), for example diagonal members (40A, 40B) each initiating approximately midway between trusses (3) and extending diagonally between cross-member (36A) and cross-member (36B), thereby forming a triangulated cross-truss configuration that provides enhanced stiffness and load distribution. Each end of cross-members (36A, 36B) is secured to trusses (3) using common fastening mechanisms including bolts, pins, and clips to facilitate field assembly, adjustment, and replacement.

[0062] Span assembly (35) and its sub-components, including cross-members (36A, 36B) and diagonal members (40A, 40B), may be formed of a composite material such as FRP to reduce the overall weight of system (1) while maintaining the required structural performance. The use of FRP for span assembly (35) is particularly advantageous because the elongated cross-members(36A, 36B) benefit from the high stiffness-to-weight ratio of pultruded composite profiles, enabling span assembly (35) to span the distance between trusses (3) and support significant utility loads without excessive weight or deflection.

[0063] The parallel arrangement of top cross-member (36A) and bottom cross-member (36B) within span assembly (35) creates a moment-resisting frame that provides increased resistance to bending loads compared to a single cross-member of equivalent weight, enabling span assembly (35) to support heavier utility loads or span longer distances than a simple beam of similar weight. In some implementations, the vertical spacing between top cross-member (36A) and bottom crossmember (36B) may be selected to optimize the moment of inertia of span assembly (35), thereby enhancing stiffness and reducing deflection under load. The parallel cross-members (36A, 36B) may also provide redundant load paths, such that loads applied to one cross-member may be partially transferred to the other cross-member through diagonal members (40A, 40B), enhancing the robustness and reliability of the utility support system.

[0064] Each end of span assembly (35) may be secured to trusses (3) using brackets, gusset plates, or direct fastening arrangements selected based on the anticipated loads and the materials of span assembly (35) and trusses (3). In some cases, the ends of cross-members (36A, 36B) may be received within slots or channels defined by vertical bracing members (5), while in other cases, the ends may be secured to the faces of vertical bracing members (5) using bolts or other mechanical fasteners. Span assembly (35) may be secured to trusses (3) at locations distinct from slots (7) used for cross-arms (13), for example by fastening ends of cross-members (36A, 36B) to the faces of vertical bracing members (5) using bolts, brackets, or gusset plates rather than passing through slots (7).

[0065] In other implementations, span assembly (35) may be positioned at vertical locations along trusses (3) where no slots (7) are defined, thereby avoiding interference with cross-arms (13) and preserving slots (7) for their intended function of receiving cross-arms (13). The selection of attachment locations and methods for span assembly (35) may be based on the desired load distribution, the number and positioning of cross-arms (13), and the overall structural requirements of system (1). In some cases, span assembly (35) may be attached to trusses (3) using the same fastener types and sizes used for other bridging members (12), thereby simplifying inventory andinstallation procedures. Tn certain implementations, span assembly (35) may include dedicated mounting brackets or cleats at each end that are configured to interface with corresponding features on vertical bracing members (5) or other truss (3) components for rapid and secure attachment.

[0066] System (1) may include external adjustable arms (27) coupled to vertical bracing members (5) via adjustment mechanisms (57) to provide additional utility support at locations and elevations independent of cross-arms (13) and span assemblies (35). Adjustable arms (27) may be selectively positioned along a vertical or horizontal axis by way of adjustment mechanism (57) and need not align with the locations of slots (7) or cross-arms (13), providing flexibility to position utility supports at any desired location along the length and height of system (1). In certain implementations, adjustable arms (27) support utilities, cabinets, doors, containment panels, or equipment, while span assemblies (35) and cross-arms (13) principally couple trusses (3) structurally and provide primary utility support. Adjustable arms (27) and adjustment mechanisms (57) may be formed of a composite material such as FRP to reduce the overall weight of system (1) and provide enhanced corrosion resistance. In some implementations, a single adjustment mechanism (57) may support two or more adjustable arms (27), enabling multiple utilities or accessories to be supported at different positions along the same vertical bracing member (5).

[0067] In some versions of adjustment mechanism (57), adjustable arms (27) may be connected by a mounting tab extending therefrom and configured to be received by a fastener of adjustment mechanism (57), such as a bolt and nut, a removable pin, or combinations thereof. In some cases, mounting tabs are welded or bonded to adjustable arms (27), or are integrally formed therewith by pultrusion or molding, to facilitate rapid installation and field adjustability. Adjustment mechanism (57) may include various features that enable selective positioning of adjustable arms (27) along vertical bracing members (5) to accommodate different utility support heights and configurations. In some implementations, adjustment mechanism (57) may include a slotted channel or track secured to vertical bracing member (5), wherein adjustable arm (27) is slidably engaged with the slotted channel to permit continuous adjustment along the length of the channel without discrete positioning limitations.

[0068] In other implementations, adjustment mechanism (57) may include a series of discrete mounting holes or apertures defined at intervals along vertical bracing member (5), whereinadjustable arm (27) may be secured at any one of the discrete mounting locations for precise, repeatable positioning. The mounting tab extending from adjustable arm (27) may be configured to slide within the slotted channel or to align with the discrete mounting holes, depending on the configuration of adjustment mechanism (57) and the desired degree of adjustability. In some cases, adjustment mechanism (57) may include a clamping element or locking mechanism configured to secure adjustable arm (27) at a desired position once adjustment is complete, preventing unintended movement during operation. The adjustable coupling between adjustable arm (27) and adjustment mechanism (57) may permit repositioning of adjustable arm (27) without requiring complete removal of the arm from system (1), thereby facilitating field adjustability and reconfiguration as utility support requirements change over time.

[0069] G. Raised Floor Installation and Utility Support

[0070] As shown in FIG. 9, system (1) may be deployed over a raised floor pedestal system (37) comprising a set of pedestals (39) arranged on a grid (e.g., 2x2 ft or 600x600 mm) configured to support a set of floor tiles (41) that form the walking surface of the data center. Raised floor systems are commonly used in data centers to create an underfloor plenum for conditioned air distribution and to provide space for routing power cables, data cables, and other utilities beneath the floor surface. Columns (21) may be positioned to match a rack spacing pattern (61) (e.g., 600 mm rack centers), thus aligning structural loads from system (1) with the underlying raised floor pedestal system (37) and ensuring that loads are transferred efficiently to the building structure. In some cases, columns (21) couple to interface plates spanning multiple pedestals (39) to distribute reaction forces across multiple support points, reducing localized loading on individual pedestals (39) and floor tiles (41).

[0071] Weight reduction achieved by using composite materials in upper unit (23) allows reduced steel thickness in lower unit (25) and can enable installations on upper building stories that impose stricter floor loading limits due to structural capacity constraints. The reduced weight of composite upper unit (23) also reduces the loads transmitted through columns (21) to the floor and underlying structure, which may permit the use of lighter columns (21), fewer attachment points, or installation on raised floor systems with lower load ratings. In some implementations, columns (21) include adjustable feet to accommodate floor tolerances, surface irregularities, andvariations in pedestal heights while maintaining plumb and level of trusses (3) for proper system alignment. The adjustable feet may include threaded shafts, leveling nuts, or other adjustment mechanisms that permit fine-tuning of column height during installation. System (1) may be provided as a pre-made kit as shown in FIG. 7, configured for flat-pack shipment and tool-assisted assembly on site, enabling rapid deployment with minimal specialized equipment or expertise.

[0072] Support for utilities extending through system (1) may be provided by various bridging members (12), including cross-arms (13), span assemblies (35), and adjustable arms (27), as well as dedicated utility support elements such as a utility casing (38) disposed on cross-member (36B). This stability allows users to route common utilities such as water piping, electricity wiring, data cables, cooling lines, and fire suppression piping through system (1) in a stable, organized structure that maintains utility positions during seismic events and normal operations. Utilities supported by system (1) may include, but are not limited to, cable trays, electrical busways, water cooling pipes, fire suppression piping, refrigerant lines, fiber optic cables, power distribution units, and lighting fixtures.

[0073] In some implementations, utilities may be supported directly on the upper surfaces of cross-arms (13), struts (17), or cross-members (36A) of span assemblies (35), providing a simple and accessible mounting arrangement. In other implementations, utilities may be suspended from the undersides of these members using hangers, clamps, J-hooks, brackets, or trapeze assemblies, which may be advantageous for routing utilities beneath the primary support level or for isolating utilities from vibration. The attachment of utilities to bridging members (12) may be accomplished using mechanical fasteners, straps, cable ties, beam clamps, or dedicated utility mounting hardware such as trapeze hangers, channel framing systems, or proprietary mounting brackets designed for specific utility types.

[0074] In some cases, system (1) may be configured to support aggregate utility loads on the order of thousands of pounds distributed across multiple bridging members (12), while maintaining the deflection performance described herein and ensuring that utility positions remain stable during seismic events. The high stiffness-to-weight ratio of FRP composite bridging members (12) enables support of significant utility loads without excessive deflection, which is important for maintaining proper utility function and preventing damage to sensitive components such as coolingpipes, electrical connections, and fiber optic cables. The load capacity of individual cross-arms (13), struts (17), and span assemblies (35) may be selected based on the anticipated utility loads, the spacing of support points along the length of system (1), and the deflection limits required for proper utility function. In certain implementations, utility loads may be distributed across multiple support points to avoid concentrated point loads that could cause localized deflection, stress concentrations, or fatigue damage in bridging members (12), and load distribution may be achieved through the use of spreader bars, continuous support channels, or multiple attachment points for heavy utilities.II. Stability

[0075] Composite aisle frame system (1) functions as a cohesive structural unit, with each component contributing to overall structural integrity and seismic resistance. As shown in FIG. 5, trusses (3) provide primary vertical support, while cross-arms (13) extending through trusses (3) act as horizontal stabilizers that couple the trusses together and reduce lateral movement during seismic events. Upper beams (9) and lower beams (11) maintain the relative positioning of trusses (3) and, together with cross-arms (13), create a three-dimensional framework capable of resisting multi-directional seismic forces. Struts (17) on the ends of cross-arms (13) enhance stability while providing utility support. Crossbeams (20) and diagonal members (22) further reinforce the structure. Columns (21) of lower unit (25) serve as the interface between system (1) and the ground, transferring loads to the floor and, in some cases, absorbing and dissipating seismic energy to reduce forces transmitted to upper unit (23).

[0076] Composite aisle frame system (1) is adaptable to different seismic environments. In lower seismic regions (ground accelerations up to about 0.2 G's), system (1) may be implemented as an all-composite design employing composite materials in both upper unit (23) and lower unit (25). In moderate seismic zones (ground accelerations up to about 0.6 G's), system (1) may be configured as a hybrid design combining a composite upper unit (23) with a steel lower unit (25), potentially reducing the need for certain braces and fasteners. In higher seismic environments (ground accelerations up to about 1.2 G's), system (1) may employ a high-seismic hybrid design with increased steel in lower unit (25) to provide additional strength and stiffness. This adaptabilityallows system (1) to meet site-specific requirements while optimizing structural performance and cost-effectiveness.

[0077] In some implementations, system (1) is configured such that maximum dynamic deflection of the coupled trusses (3) under a design seismic event is no greater than approximately one inch (about 25 mm) in any principal direction, thereby maintaining a desired clearance from adjacent equipment such as racks (60). As used herein, the term "design seismic event" refers to a seismic occurrence characterized by ground accelerations and spectral characteristics against which composite aisle frame system (1) is engineered to perform. In some implementations, the design seismic event may correspond to ground accelerations associated with a particular seismic design category or site class as defined by applicable building codes or industry standards. For example, in low seismic regions, the design seismic event may correspond to ground accelerations up to about 0.2 G's, while in moderate seismic regions, the design seismic event may correspond to ground accelerations up to about 0.6 G's. In high seismic regions, such as certain areas of California, the design seismic event may correspond to ground accelerations up to about 1.2 G's or higher. The configuration of composite aisle frame system (1), including the selection of materials for upper unit (23) and lower unit (25), may be tailored based on the anticipated design seismic event for a particular installation site.

[0078] The above deflection performance may be achieved using composite members exhibiting a longitudinal flexural modulus in the range of about 5.5 to about 6.0 million psi, in combination with trusses (3), bridging members (12), and tailored mass distribution.

[0079] Weight reductions using FRP composite elements in system (1) relative to all-steel constructions may be on the order of about 50%, providing advantages for multi-story installations and raised floor environments. Cross-arms (13), adjustable arms (27), and span assemblies (35) may be rated to support utilities such as water cooling pipes and electrical bus ducts on the order of thousands of pounds in aggregate while meeting the above deflection criterion. In some cases, external adjustable arms (27) are used predominantly for utility support and enclosure accessories (doors, panels), while internal bridging members (12) primarily provide frame coupling and stiffness.III. Composite Materials

[0080] The composite materials described herein comprise two or more constituent components, generally including a matrix and one or more reinforcing elements. The matrix may comprise a polymer, metal, ceramic, or other suitable material, while the reinforcing elements may include fibers, particulates, whiskers, or laminates. These combinations may be tailored to provide a high strength-to-weight ratio, improved corrosion resistance, and enhanced structural stability.

[0081] In some implementations, the composite material comprises a polymer matrix reinforced with continuous fibers selected from carbon fibers, glass fibers, aramid fibers, or natural fibers. The fibers are embedded within the polymer matrix to form a fiber reinforced polymer (FRP) composite. A modular pultruded FRP structure may be utilized for constructing some or all elements of composite aisle frame system (1). The pultrusion process facilitates continuous manufacture of components having a constant cross-sectional profile, which is advantageous for fabricating long structural elements requiring high stiffness and low weight, such as trusses (3) and cross-arms (13). In some versions of system (1), cross-arms (13) and / or upper beams (9) are formed from FRP while vertical bracing members (5) are formed from steel or aluminum, reducing overall system weight while maintaining sufficient strength.

[0082] While FRP is described as one example, the present disclosure is not limited to FRP compositions. Alternative composite materials, including metal matrix composites (MMCs) and ceramic matrix composites (CMCs), may also be utilized depending on performance requirements and environmental conditions.

[0083] Certain FRP implementations in system (1) utilize E-glass reinforcements and resin systems formulated to achieve a longitudinal flexural modulus of about 5.5 to 6.0 million psi, which exceeds commodity FRP values (e.g., about 1.8 to 2.2 million psi) while retaining favorable strength-to-weight metrics. Such composite members may yield mass reductions approaching about 50% compared to all-steel aisle frames, with additional savings relative to aluminum constructions. System (1) may be tuned through fiber orientation, lay-up configuration, and pultrusion parameters to meet the deflection objectives described herein.

[0084] The selection of E-glass reinforcement elements and resin systems to achieve the desired flexural modulus may involve several factors. The resin system may comprise a thermosetting polymer such as polyester, vinyl ester, or epoxy. Vinyl ester resins may be selectedfor enhanced corrosion resistance, while epoxy resins may be selected for higher mechanical performance. The fiber volume fraction, representing the proportion of reinforcing fibers relative to total composite volume, may be adjusted to influence the resulting flexural modulus. In some cases, fiber volume fractions in the range of about 50% to about 70% may be employed to achieve the target modulus range. The orientation of E-glass fibers may also affect the longitudinal flexural modulus, with unidirectional arrangements generally providing higher modulus values in the fiber direction compared to woven or random arrangements. In certain implementations, a combination of unidirectional and off-axis fiber layers may be used to balance longitudinal stiffness with transverse strength and shear performance.IV. Exemplary Combinations

[0085] The following examples relate to various non-exhaustive ways in which the teachings herein may be combined or applied. It should be understood that the following examples are not intended to restrict the coverage of any claims that may be presented at any time in this application or in subsequent filings of this application. No disclaimer is intended. The following examples are being provided for nothing more than merely illustrative purposes. It is contemplated that the various teachings herein may be arranged and applied in numerous other ways. It is also contemplated that some variations may omit certain features referred to in the below examples. Therefore, none of the aspects or features referred to below should be deemed critical unless otherwise explicitly indicated as such at a later date by the inventors or by a successor in interest to the inventors. If any claims are presented in this application or in subsequent filings related to this application that include additional features beyond those referred to below, those additional features shall not be presumed to have been added for any reason relating to patentability.

[0086] Example 1

[0087] A composite aisle frame system, comprising: (a) a first truss; (b) a second truss; and (c) a bridging member extending between the first truss and the second truss, wherein at least a portion of at least one of the first truss, the second truss, and the bridging member is formed from a composite material.

[0088] Example 2

[0089] The prior or any of the subsequent Examples, wherein the bridging member extends through the first truss.

[0090] Example 3

[0091] Any of the prior or subsequent Examples, wherein the first truss includes: (a) a vertical bracing member; and (b) a slot defined by the vertical bracing member, wherein the bridging member extends through the slot to extend through the first truss.

[0092] Example 4

[0093] Any of the prior or subsequent Examples, further comprising a strut disposed on the bridging member.

[0094] Example 5

[0095] Any of the prior or subsequent Examples, wherein the first truss includes: (a) a peripheral surface, wherein the peripheral surface is disposed between the slot and an outer edge of the vertical bracing member; and (b) an opening defined by the first truss, wherein the opening is proximate the peripheral surface.

[0096] Example 6

[0097] Any of the prior or subsequent Examples, further comprising a containment panel abutting the peripheral surface to seal the opening, wherein the containment panel is configured to separate a stream of incoming cool air from a stream of hot exhaust air.

[0098] Example 7

[0099] Any of the prior or subsequent Examples, wherein the bridging member extends from a first end to a second end, wherein the first end of the bridging member is secured to the first truss, wherein the second end of the bridging member is secured to the second truss.

[0100] Example 8

[0101] Any of the prior or subsequent Examples, wherein the bridging member comprises a span assembly, wherein the span assembly includes a top cross-member and a bottom crossmember, wherein the top cross-member extends parallel to the bottom cross-member.

[0102] Example 9

[0103] Any of the prior or subsequent Examples, further comprising: (a) an adjustment mechanism secured to the first truss; and (b) an adjustable arm, wherein the adjustable arm is adjustably coupled to the adjustment mechanism.

[0104] Example 10

[0105] Any of the prior or subsequent Examples, wherein the adjustable arm is a first adjustable arm, and further comprising a second adjustable arm, wherein the second adjustable arm is adjustably coupled to the adjustment mechanism.

[0106] Example 11

[0107] Any of the prior or subsequent Examples, wherein the composite material comprises a fiber reinforced polymer (FRP) composite.

[0108] Example 12

[0109] Any of the prior or subsequent Examples, wherein the fiber reinforced polymer (FRP) composite comprises a plurality of E-glass reinforcement elements combined with an amount of resin, wherein the E-glass reinforcement elements and the amount of resin are selected to achieve a longitudinal flexural modulus in the fiber reinforced polymer (FRP) of between 5.5 and 6.0 million psi.

[0110] Example 13

[0111] Any of the prior or subsequent Examples, wherein the system is configured such that a maximum dynamic deflection of the first truss, the second truss, and the bridging member under a design seismic event is no greater than approximately one inch in any principal direction.

[0112] Example 14

[0113] A composite aisle frame system, comprising: (a) a first truss, (b) a second truss, and (c) a bridging member having a first end, a middle portion, and a second end, wherein the middle portion is disposed between the first truss and the second truss, wherein the bridging member comprises a composite material.

[0114] Example 15

[0115] Any of the prior or subsequent Examples, wherein the bridging member extends through the first truss and the second truss.

[0116] Example 16

[0117] Any of the prior or subsequent Examples, wherein the first truss defines a first slot therethrough, wherein the second truss defines a second slot, wherein the bridging member extends through the first slot and the second slot.

[0118] Example 17

[0119] Any of the prior or subsequent Examples, further comprising a first strut disposed on the first end of the bridging member, wherein the first strut has a profile larger than the first slot to thereby inhibit lateral displacement of the bridging member out of the first slot.

[0120] Example 18

[0121] Any of the prior or subsequent Examples, wherein the first truss includes: (a) a peripheral surface, wherein the peripheral surface is disposed proximate the first slot; (b) an opening defined by the first truss, wherein the opening is proximate the peripheral surface; and (c) a containment panel abutting the peripheral surface and secured to the first truss to seal off the opening.

[0122] Example 19

[0123] A composite aisle frame system, comprising: (a) an upper unit comprising: (i) a first truss comprising a first vertical bracing member, wherein the first vertical bracing member defines a first slot therethrough, (ii) a second truss comprising a second vertical bracing member, whereinthe second vertical bracing member defines a second slot therethrough, wherein the second slot is aligned with the first slot, (iii) a cross-arm extending through the first slot and the second slot, wherein the cross-arm extends from a first end to a second end, wherein the cross-arm comprises a composite material, (iv) a pair of struts comprising a first strut disposed on the first end of the cross-arm and a second strut disposed on the second end of the cross-arm, wherein each of the first strut and the second strut presents a profile larger than the first slot and the second slot, (v) a peripheral surface disposed between the first slot and an outer edge of the first vertical bracing member, and (vi) a containment panel abutting the peripheral surface to seal an opening defined by the first truss, wherein the containment panel is positioned on an inside surface of the first truss; and (b) a lower unit comprising a plurality of columns configured to support the upper unit, wherein the plurality of columns comprise a metallic material selected from steel and aluminum.

[0124] Example 20

[0125] Any of the prior Examples, wherein the system is configured such that a maximum dynamic deflection of the first truss, the second truss, and the cross-arm under a design seismic event is no greater than approximately one inch in any principal direction.V. Miscellaneous

[0126] It should be understood that any of the examples described herein may include various other features in addition to or in lieu of those described above. By way of example only, any of the examples described herein may also include one or more of the various features disclosed in any of the various references that are incorporated by reference herein.

[0127] It should be understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. that are described herein. The abovedescribed teachings, expressions, embodiments, examples, etc. should therefore not be viewed in isolation relative to each other. Various suitable ways in which the teachings herein may be combined will be readily apparent to those of ordinary skill in the art in view of the teachings herein. Such modifications and variations are intended to be included within the scope of the claims.

[0128] It should be appreciated that any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

[0129] Having shown and described various versions of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, versions, geometries, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.

Claims

CLAIMS1. A composite aisle frame system, comprising:(a) a first truss;(b) a second truss; and(c) a bridging member extending between the first truss and the second truss,wherein at least a portion of at least one of the first truss, the second truss, and the bridging member is formed from a composite material.

2. The composite aisle frame system of claim 1, wherein the bridging member extends through the first truss.

3. The composite aisle frame system of claim 1, wherein the first truss includes:(a) a vertical bracing member; and(b) a slot defined by the vertical bracing member,wherein the bridging member extends through the slot to extend through the first truss.

4. The composite aisle frame system of claim 3, further comprising a strut disposed on the bridging member.

5. The composite aisle frame system of claim 3, wherein the first truss includes:(a) a peripheral surface, wherein the peripheral surface is disposed between the slot and an outer edge of the vertical bracing member; and(b) an opening defined by the first truss, wherein the opening is proximate the peripheral surface.

6. The composite aisle frame system of claim 5, further comprising a containment panel abutting the peripheral surface to seal the opening, wherein the containment panel is configured to separate a stream of incoming cool air from a stream of hot exhaust air.

7. The composite aisle frame system of claim 1, wherein the bridging member extends from a first end to a second end, wherein the first end of the bridging member is secured to the first truss, wherein the second end of the bridging member is secured to the second truss.

8. The composite aisle frame system of claim 7, wherein the bridging member comprises a span assembly, wherein the span assembly includes a top cross-member and a bottom cross-member, wherein the top cross-member extends parallel to the bottom cross-member.

9. The composite aisle frame system of claim 1, further comprising:(a) an adjustment mechanism secured to the first truss; and(b) an adjustable arm, wherein the adjustable arm is adjustably coupled to the adjustment mechanism.

10. The composite aisle frame system of claim 9, wherein the adjustable arm is a first adjustable arm, and further comprising a second adjustable arm, wherein the second adjustable arm is adjustably coupled to the adjustment mechanism.

11. The composite aisle frame system of claim 1, wherein the composite material comprises a fiber reinforced polymer (FRP) composite.

12. The composite aisle frame system of claim 11 , wherein the fiber reinforced polymer (FRP) composite comprises a plurality of E-glass reinforcement elements combined with an amount of resin, wherein the E-glass reinforcement elements and the amount of resin are selected to achieve a longitudinal flexural modulus in the fiber reinforced polymer (FRP) of between 5.5 and 6.0 million psi.

13. The composite aisle frame system of claim 1, wherein the system is configured such that a maximum dynamic deflection of the first truss, the second truss, and the bridging member under a design seismic event is no greater than approximately one inch in any principal direction.

14. A composite aisle frame system, comprising:(a) a first truss,(b) a second truss, and(c) a bridging member having a first end, a middle portion, and a second end, wherein the middle portion is disposed between the first truss and the second truss, wherein the bridging member comprises a composite material.

15. The composite aisle frame system of claim 14, wherein the bridging member extends through the first truss and the second truss.

16. The composite aisle frame system of claim 15, wherein the first truss defines a first slot therethrough, wherein the second truss defines a second slot, wherein the bridging member extends through the first slot and the second slot.

17. The composite aisle frame system of claim 16, further comprising a first strut disposed on the first end of the bridging member, wherein the first strut has a profile larger than the first slot to thereby inhibit lateral displacement of the bridging member out of the first slot.

18. The composite aisle frame system of claim 16, wherein the first truss includes:(a) a peripheral surface, wherein the peripheral surface is disposed proximate the first slot;(b) an opening defined by the first truss, wherein the opening is proximate the peripheral surface; and(c) a containment panel abutting the peripheral surface and secured to the first truss to seal off the opening.

19. A composite aisle frame system, comprising:(a) an upper unit comprising:(i) a first truss comprising a first vertical bracing member, wherein the first vertical bracing member defines a first slot therethrough,(ii) a second truss comprising a second vertical bracing member, wherein the second vertical bracing member defines a second slot therethrough, wherein the second slot is aligned with the first slot,(iii) a cross-arm extending through the first slot and the second slot, wherein the cross-arm extends from a first end to a second end, wherein the cross-arm comprises a composite material,(iv) a pair of struts comprising a first strut disposed on the first end of the crossarm and a second strut disposed on the second end of the cross-arm, wherein each of the first strut and the second strut presents a profile larger than the first slot and the second slot,(v) a peripheral surface disposed between the first slot and an outer edge of the first vertical bracing member, and(vi) a containment panel abutting the peripheral surface to seal an opening defined by the first truss, wherein the containment panel is positioned on an inside surface of the first truss; and(b) a lower unit comprising a plurality of columns configured to support the upper unit, wherein the plurality of columns comprise a metallic material selected from steel and aluminum.

20. The composite aisle frame system of claim 19, wherein the system is configured such that a maximum dynamic deflection of the first truss, the second truss, and the cross-arm under a design seismic event is no greater than approximately one inch in any principal direction.

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