Double Back Stop Structure for Pallet Rack Separation
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Solution Overview
Problem
Conventional methods for maintaining a minimum separation between pallets on adjacent racks are cumbersome to install and prone to failure under lateral loads, as they require extensive attachment means and are structurally weak.
Innovation Solution
A double back stop system is introduced, comprising a first and second back stop attached to each rack, connected by a middle section to maintain a minimum separation, which is formed from a bent integral piece of material to prevent lateral movement and enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional Z-stop brackets are attached to racks using bolts, then separation between pallets is provided, but the structure is cumbersome to install and structurally weak under lateral loads
Solution Approach 1:
The patent combines multiple separate Z-stop brackets and their attachment means into a single integrated double back stop structure. This unified structure attaches to both racks simultaneously, eliminating the need for separate attachment operations and reducing the overall complexity of the installation process while maintaining structural integrity under lateral loads.
Solution Approach 2:
The double back stop structure is divided into distinct functional segments: first back stop members for the first rack, second back stop members for the second rack, and middle sections connecting them. This segmentation allows each component to be optimized for its specific function while being part of an integrated whole, improving both installation ease and structural reliability.
2Reliability
If multiple attachment means are used to secure Z-stop brackets, then the separation is maintained, but the installation process becomes extensive and time-consuming
Solution Approach 1:
The patent merges multiple attachment operations into a single installation process. The double back stop structure is designed to attach to both racks simultaneously, reducing the number of separate attachment steps required. This consolidation maintains the necessary separation between pallets while significantly reducing installation time and labor requirements.
Solution Approach 2:
The double back stop structure is pre-configured with all necessary attachment points and connecting elements before installation. The middle sections are already positioned to maintain the correct minimum separation distance, allowing installers to complete the entire separation system in one operation rather than making multiple adjustments during installation.
3Ease of operation
If separate Z-stop brackets are attached to each rack, then pallet separation is achieved, but the structure fails under significant lateral forces
Solution Approach 1:
The patent combines separate Z-stop brackets into a unified double back stop structure that spans both racks. This merged structure distributes lateral loads across both racks and the connecting middle sections, providing significantly greater lateral load resistance than separate brackets could achieve individually, while maintaining the ease of pallet separation operation.
Solution Approach 2:
The double back stop structure functions as a composite system combining multiple structural elements (back stop members, middle sections, attachment points) into a unified load-bearing assembly. This composite structure leverages the combined strength of all components to resist lateral forces that would overwhelm individual Z-stop brackets, while preserving the operational simplicity of pallet separation.
Data Source
AI summary
A system is provided for maintaining a minimum separation between a first pallet positioned on a first rack and a second pallet positioned on a second rack. The system comprises a double back stop that includes a first back stop attached to the first rack to prevent lateral movement of the first pallet beyond the first back stop. The double back stop also includes a second back stop attached to the second rack to prevent lateral movement of the second pallet beyond the second back stop. A minimum distance is maintained between the first and second backstops such that the minimum separation is maintained. The double back stop also includes a middle section to connect the first back stop to the second back stop. Methods are also provided for forming the double back stop and for maintaining the minimum separation between the first pallet and the second pallet.