Pallet Rack Grate Press-Fit Structure for Lower Weight
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Solution Overview
Problem
Existing grate designs for panel and heavy-duty shelves are heavy and costly due to the need for high material strength and stability, which increases the load-bearing capacity but also requires extensive monitoring of welding parameters for quality control, potentially leading to weld seam failures and destabilization.
Innovation Solution
The grate design features long sides with profiles that include cross members with open U-, L-, or V-shaped profiles, where the first leg of the profile is inserted into punchings on the cross members, providing vertical fixation and embossments for horizontal fixation, reducing weight and material costs while maintaining stability through a combination of positive and non-positive connection methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid steel materials are used for long sides and longitudinal webs to ensure stability and load-bearing capacity, then the structural strength is improved, but the dead weight of the grate increases significantly
Solution Approach 1:
The patent applies hollow profile structures with thin-walled cross-sections (e.g., I-profiles, channels, tubes) that provide high strength-to-weight ratios. The hollow profiles maintain structural integrity while significantly reducing material mass compared to solid steel sections, directly addressing the contradiction between load-bearing capacity and dead weight.
Solution Approach 2:
The grate combines different materials strategically: aluminum or steel for the hollow profile framework providing structural strength, and plastic or rubber for the top layer providing load distribution and protection. This composite approach optimizes the strength-weight ratio by using materials where each contributes its superior properties.
2Ease of manufacture
If welding processes are used to join cross members to long sides, then the manufacturing ease is improved, but the manufacturing precision and reliability deteriorate due to the need for constant monitoring and regulation of welding parameters
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with mechanical connection methods such as rivets, screws, clips, or press-fitted joints. This substitution eliminates the need for complex welding parameter monitoring and regulation while maintaining connection strength, directly resolving the contradiction between manufacturing ease and precision.
Solution Approach 2:
The use of simple mechanical fasteners like rivets or clips replaces expensive, complex welding operations. These mechanical connectors are easier to install, require less skilled labor, and eliminate the need for expensive welding equipment and parameter control systems.
3Object-affected harmful factors
If the open spaces in grates are increased to allow extinguishing media to pass through, then the fire safety is improved, but the load-bearing capacity deteriorates
Solution Approach 1:
The hollow profile structures with thin-walled sections maintain sufficient structural strength while creating inherent open spaces between the profiles. The topology of the hollow sections themselves provides the necessary openings for fire safety without requiring additional cutouts that would compromise structural integrity.
Solution Approach 2:
The combination of a rigid hollow profile framework with a flexible top layer (plastic or rubber) creates a structure where the framework provides load-bearing capacity and the spacing between framework elements provides fire safety openings. The composite structure allows optimization of each component for its primary function.
Data Source
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AI summary
Grate (1) for use as a shelf for pallet racks or heavy duty racks having two longitudinal sides (2a, 2b) and cross members (3a-3j) arranged between the longitudinal sides, wherein the longitudinal sides are in the form of a profile in cross section, wherein the profile comprises at least one first leg (L1) and a second leg (L2) arranged substantially at right angles to the first leg, wherein at least two of the cross members have an open - in particular U- or V- or L-shaped - profile in cross section, the open side of said profile being oriented towards the underside (U) of the grate, wherein each of these cross members has at least two punch holes at each end, wherein the first leg of the profile is arranged in each punch hole and is connected firmly thereto via a connecting method, characterized in that the connecting method is a form- and/or force-fitting connecting method and in that the first leg of the profile has at least one deformation.