Perforated decking

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Solution Overview

Problem

Current decking panels are often too heavy and do not meet state and local building codes, particularly regarding fire safety and water penetration requirements, and lack attachment points for accessories to organize and separate loads.

Innovation Solution

A perforated decking panel design featuring laterally spaced parallel structural beams and a metal sheet with top and bottom perforations, allowing for attachment of divider walls and stop walls, and configured as either horizontal or sloped gravity feed panels to enhance structural integrity and compliance with building codes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If traditional decking panels are used, then structural strength is maintained, but weight is excessive and building code compliance is poor

Engineering Contradiction:

Improvedecking panel weightVSAvoidbuilding code compliance

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent applies porous materials by incorporating a perforated metal sheet with multiple openings throughout the decking panel structure. This perforated design reduces the overall weight of the panel while maintaining structural integrity through the distributed pattern of holes, thereby achieving both weight reduction and compliance with building codes that require certain levels of material density and strength.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent employs composite materials by combining multiple materials in a layered structure: a perforated metal sheet, structural beams, and infill materials. This composite construction allows each material to contribute its optimal properties - the metal sheet provides structural framework and weight reduction, while infill materials provide strength and code compliance - thereby resolving the contradiction between light weight and reliable performance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If traditional decking panels are used, then structural integrity is maintained, but fire safety and water penetration compliance is poor

Engineering Contradiction:

Improvefire safety and water penetration complianceVSAvoiddecking panel weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The perforated metal sheet with controlled opening patterns enables water to pass through while maintaining fire rating compliance through appropriate material selection and hole distribution. The porous structure allows water penetration as required by building codes while the metal material and perforation pattern can be designed to meet fire safety requirements, all while keeping the panel lightweight.

Inventive Principle:

Principle #31Porous materials

3Strength

If solid metal sheets are used, then structural strength is improved, but weight increases and accessory attachment capability is poor

Engineering Contradiction:

Improvedecking panel strengthVSAvoiddecking panel weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The perforated metal sheet provides structural strength through its rigid metal construction and distributed perforation pattern, while the openings reduce overall weight compared to a solid sheet. The perforations are strategically placed to maintain structural integrity at critical locations while allowing weight reduction in less critical areas.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The perforated metal sheet serves multiple functions simultaneously: it provides structural support, reduces weight, enables water penetration, and offers attachment points for accessories through the perforations. This multi-functionality resolves the contradiction between strength and weight by making the same structural element serve multiple purposes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If traditional decking panels are used, then simplicity of design is maintained, but accessory attachment capability is poor

Engineering Contradiction:

Improveaccessory attachment capabilityVSAvoiddecking panel structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The decking panel is segmented into distinct functional components: the perforated metal sheet framework, structural beams, and infill materials. This segmentation allows each component to be optimized for its specific function while maintaining overall structural integrity, and the modular nature facilitates easier assembly and accessory attachment.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS10377569B1Perforated decking

Publication Date: 2019.08.13 NASHVILLE WIRE PROD MFG CO LLC

AI summary

The present invention relates to a horizontal or slopped decking panel for use with a storage rack. The decking panel may include a plurality of laterally spaced parallel structural beams have first and second ends and a metal sheet. The metal sheet may extend around and under the first and second ends of the structural beams to define a first panel edge and a first bottom return sheet portion. The metal sheet may extend around and under the second ends of the structural beams to define a second panel edge and a second bottom return sheet portion. The metal sheet may have a plurality of top perforations. The first and second bottom return sheet portions may have first and second rows, respectively, of bottom perforations. Each of the bottom perforations may be aligned with one of the top perforations so that a post of a divider wall can be received.