Single-Sheet Rack Decking With Folded Cross Rails and Safe Edges

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Solution Overview

Problem

Storage rack systems often lack standardized shelving or decking, leading to customization needs for end users and potential product damage or snagging due to protuberances and sharp edges.

Innovation Solution

A decking system formed from a single sheet of metal, folded and secured to create parallel deck members with cross rails, which can be easily mounted onto storage rack systems, minimizing sharp edges and protuberances while allowing for customizable dimensions and features like access holes or perforations for fire safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If decking is customized for each storage rack system, then adaptability to different configurations is improved, but manufacturing complexity and time increase

Engineering Contradiction:

Improveadaptability to different storage rack configurationsVSAvoidmanufacturing complexity of decking

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The decking is segmented into multiple identical modular units, each comprising a standardized frame with panels. These modules can be manufactured using the same process and then configured in different arrangements to suit various storage rack systems, achieving adaptability without increasing manufacturing complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The decking modules are designed with universal features including standardized mounting mechanisms that can attach to different rack configurations, adjustable shelving positions, and interchangeable panels, allowing a single design to serve multiple storage rack system types

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If traditional decking with joints and connections is used, then structural strength is improved, but sharp edges and protuberances increase causing product damage

Engineering Contradiction:

Improvestructural strength of deckingVSAvoidsharp edges and protuberances causing product damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Multiple decking components (frames, panels, connectors) are merged into a single integrated modular unit with rounded external surfaces. The joints and connections are internal to the module, eliminating exposed sharp edges and protuberances while maintaining structural strength through internal reinforcement

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The external surfaces of the decking modules, particularly edges and corners, are designed with curved and rounded profiles rather than sharp angles. This spheroidality principle reduces harmful sharp edges while the internal structure maintains necessary strength through optimized geometric configurations

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Reliability

If decking is designed with fire safety features like access holes, then fire safety compliance is improved, but structural integrity may be compromised

Engineering Contradiction:

Improvefire safety complianceVSAvoidstructural integrity of decking

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

Fire safety access holes and perforations are strategically positioned in specific local areas of the decking panels where they provide fire suppression access while minimizing impact on overall structural integrity. The panel design varies local properties (openings) without compromising global strength

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The decking panels utilize composite material construction combining metal frames with reinforced panel materials that can accommodate fire safety openings while maintaining structural strength. The composite design allows strategic placement of access holes in non-critical areas

Inventive Principle:

Principle #40Composite materials

4Ease of operation

If decking is made from multiple separate pieces, then ease of assembly is improved, but shipping and storage space efficiency decreases

Engineering Contradiction:

Improveease of assembly of deckingVSAvoidshipping and storage space efficiency

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

Multiple decking components are merged into integrated modular units that ship and store as compact single pieces. The modules are designed to nest within each other when empty, significantly reducing shipping and storage volume while maintaining ease of assembly through simple connection mechanisms

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS7891507B2Storage rack decking derived from a single sheet of sheet metal

Publication Date: 2011.02.22 SHETLER JAKIE

AI summary

Decking for a storage rack system is presented in which the decking is formed from a single sheet of sheet metal. The single sheet of sheet metal is cut and folded to form a plurality of parallel deck members having an upper deck surface, a lower deck surface, and sidewalls. The single sheet of sheet metal further folded to form two cross rails perpendicular to the deck members at either end of the deck members. Each cross rail comprises a lower rail surface and a side rail surface. Each lower rail surface overlaps at least a portion of the lower deck surface of the deck members. The lower rail surfaces are secured to the lower deck surface at the overlap of the lower rail surface and the lower deck surface.