Patent Grant
11583073
This invention relates to shelving units, and more particularly to shelf support beams to increase the load-bearing capacity of shelving units.
Shelving units are commonly used for storing various items in a space-efficient manner. Such units typically include four vertical support posts arranged at corners of a generally rectangular pattern. Horizontal front and rear shelf support beams extend between the two front corner support posts and between the two rear corner support posts. Shorter horizontal shelf support beams are often positioned on opposing sides of the unit and extend between a front corner support post and a rear corner support post. In a conventional arrangement, such shelving units define multiple shelves and supporting beams one above the other with the corner support posts and shelf support beams of metal. For example, these components are often formed of sheet metal or steel and, in combination with shelves, are generally referred to as steel shelving or storage units.
As loads are applied to a shelving unit, such as by loading heavy items onto a shelf, each shelf may bow or bend. Bowing and bending beyond a limit can lead to shelving failure, particularly when bowing results in strain beyond the unit's capacity. For example, undue bowing or bending of a shelving unit under load could permanently deform the shelf, allowing the shelf to pull away from the shelf support beams of the shelving unit thereby rendering the shelf and/or shelving unit inoperable for future use, or the shelf could catastrophically fail.
While metal shelving units are generally successful for their intended purpose and remain useful and popular with consumers, manufacturers and other providers continually strive to improve upon their design and load-carrying capacity. In this regard, it is desirable to significantly increase the load capacity of shelving units without a significant increase in manufacturing cost and/or without a significant increase in weight of the shelving unit.
Embodiments in accordance with the invention address these and other deficiencies in conventional metal shelving units by at least significantly increasing the load capacity relative to existing metal shelving units without increasing related material or manufacturing costs. In one embodiment, a shelf support beam for use in a shelving unit to support a shelf includes a structural member having a C-shaped cross-section. In the cross-section, a web separates a top flange from a bottom flange. The top flange is configured to support the shelf. The web, the top flange, and the bottom flange define a channel. The channel defines a cavity height. And, the top flange and the bottom flange define a top flange width and a bottom flange width, respectively. A ratio of the cavity height to a sum of the top flange width and the bottom flange width is greater than 1.
In one embodiment, the C-shaped cross-section has a moment of inertia of greater than 0.40.
In one embodiment, the C-shaped cross-section has a moment of inertia of greater than 0.45.
In one embodiment, the C-shaped cross-section has a moment of inertia of at least 0.46.
In one embodiment, the top flange includes an elevated portion and a lower or shelf support portion separated by a sidewall and having an S-shaped configuration with the shelf support portion being configured to support the shelf and the sidewall being configured to prevent lateral motion of the shelf toward the web. The cavity height is defined between the shelf support portion and the bottom flange.
In one embodiment, the ratio is at least 1.20.
In one embodiment, the ratio is about 1.40.
In one embodiment, the cavity height is greater than 2.50 inches (6.35 centimeters) and is less than 5.375 inches (13.65 centimeters).
In one embodiment, the C-shaped cross-section has a centroid and the centroid is within 0.25 inch (0.635 centimeter) of the web.
In one embodiment, the web includes a recessed region in which the structural member is offset in a direction into the channel.
In one embodiment, the recessed region is at least 50% of the overall height of the structural member.
In one embodiment, the recessed region is in a range of 50% to 70% of the overall height of the structural member.
In one embodiment, the recessed region is at least 70% of the overall height of the structural member.
In one embodiment, the web includes a recessed region in which the structural member is offset in a direction into the channel and wherein the C-shaped cross-section has a centroid and the centroid is within 0.125 inch (0.3175 centimeter) of the recessed region.
In one embodiment, the recessed region is at least 50% of the overall height of the structural member.
In one embodiment, the recessed region is in a range of 50% to 70% of the overall height of the structural member.
In one embodiment, the recessed region is at least 70% of the overall height of the structural member.
In one embodiment, the C-shaped cross-section has a gauge of 0.054 inch (0.1372 centimeter).
In one embodiment, the C-shaped cross-section has a strip width of 5.735 inch (14.57 centimeters).
In one embodiment, the C-shaped cross-section has a strip width of 0.054 inch (0.1372 centimeter).
In one embodiment, a shelving unit includes a plurality of posts; and a plurality of shelf support beams of any one of the embodiments identified above attached to the plurality of posts. A shelf is seated on the shelf support beams.
According to one aspect of the invention, there is a method of manufacturing a shelf support beam of any one of the embodiments identified above.
In an embodiment, a shelf support beam for use in a shelving unit to support a shelf includes a structural member having a C-shaped cross-section. In the cross-section a web separates a top flange that is configured to support the shelf from a bottom flange. The web, the top flange, and the bottom flange define a channel. The C-shaped cross-section has a moment of inertia greater than 0.40.
In one embodiment, the C-shaped cross-section has an overall height of greater than 2.977 inches (7.562 centimeters).
In one embodiment, the C-shaped cross-section has a moment of inertia of greater than 0.45.
In one embodiment, the C-shaped cross-section has a moment of inertia of at least 0.46.
In one embodiment, the C-shaped cross-section has a strip width of 5.735 inches (14.57 centimeters).
In one embodiment, the C-shaped cross-section has a gauge of 0.054 inch (0.1372 centimeter).
In one embodiment, the top flange includes an elevated portion and a lower or shelf support portion separated by a sidewall and having an S-shaped configuration. The shelf support portion is configured to support the shelf and the sidewall is configured to prevent lateral motion of the shelf toward the web. The cavity height is defined between the shelf support portion and the bottom flange.
In one embodiment, the channel has a cavity height, the top flange, and the bottom flange define a top flange width and a bottom flange width, respectively. A ratio of the cavity height to a sum of the top flange width and the bottom flange width is greater than 1.
In one embodiment, the ratio is at least 1.20.
In one embodiment, the ratio is about 1.40.
In one embodiment, a shelving unit includes a plurality of posts; a plurality of shelf support beams of any one of the embodiments identified above attached to the plurality of posts; and a shelf seated on the shelf support beams.
According to one aspect of the invention, there is a method of manufacturing a shelf support beam of any one of the embodiments identified above.
Various additional features and advantages of the invention will become more apparent to those of ordinary skill in the art upon review of the following detailed description of one or more illustrative embodiments taken in conjunction with the accompanying drawings. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the detailed description given below, serve to explain the one or more embodiments of the invention.
To these and other ends, in one embodiment and with reference to
With continued reference to
The horizontal shelf support beams 14 are configured to support a shelf 22. Items (not shown) may be stored on the shelf 22 in the normal course of using the shelving unit 10. These items produce a load due to gravity on each of the shelf support beams 14, which is transferred to the posts 12. One or more of the shelves 22 of the shelving unit 10, and preferably each of the shelves 22 of the shelving unit 10, may be configured as a wire rack. Other shelf configurations, such as solid shelves, are also possible.
In an exemplary embodiment, the horizontal shelf support beams 14 are configured to be selectively coupled to the posts 12 via releasable fastening means fully described in U.S. application Ser. No. 16/130,398. By way of example, each of the horizontal shelf support beams 14 may include one or more locking pins 24 that are configured to be received within corresponding H-shaped or V-shaped keyholes 26 that are distributed along the length of the corner posts 12. The horizontal shelf support beams 14 couple to the corner posts 12 at the keyholes 26 and may be moved vertically with respect to the posts 12 such that the number of horizontal shelf support beams 14 and their respective heights along the posts 12 may be varied. As shown, the shelving unit 10 includes four horizontal shelves 22 supported by shelf support beams 14 according to embodiments of the invention. However, it will be appreciated that any number of shelves 22 and corresponding horizontal shelf support beams 14 may be used.
As described above, according to aspects of the present invention, the horizontal shelf support beams 14 having increased load carrying capacity relative to existing support beams can be produced with little or no additional material. More particularly, such horizontal shelf support beams 14 can be produced with existing materials and existing resources, and can be produced in conformity with existing manufacturing techniques. Thus, embodiments of the invention do not significantly add to the manufacturing cost of the shelving unit 10 while providing superior loading performance. To these and other ends, Applicant discovered that maximizing a moment of inertia of a cross-section of a beam will increase the load carrying capacity of the shelf support beam 14 relative to existing beams.
By way of comparison only and with reference to
In that C-shaped cross-sectional configuration, section 32 includes a web 40, which forms a vertical portion of the structural member 30 during use. The section 34 defines a top flange 42 and is configured to receive a shelf. The top flange 42 extends generally inwardly in a shelving unit (e.g.,
With reference to
(1) a strip width of 5.735 inches (14.57 centimeters) (the strip width of the structural member 30 in the cross-section of
(2) a weight of 6.8 pounds (3.084 kilograms), the weight is an approximation based on the available gage and dimensional variation of the strip from which the beam is made,
(3) a cavity height (A1) (
(4) a gauge of 0.054 inch (0.1372 centimeter),
(5) a top flange width (A2) of 1.385 inches (3.518 centimeters) (as measured from the end 54 to the inwardly facing surface of the web 40),
(6) a bottom flange width (A3) of 1.250 inches (3.175 centimeters) (as measured from the end 56 to the inwardly facing surface of the web 40),
(7) a web height (A4) of 2.577 inches (6.546 centimeters),
(8) an overall height (A5) of 2.977 inches (7.562 centimeters), and
(9) a hardness of 12 on the Webster scale.
The moment of inertia for the shelf support beam 28 was calculated for each section 32, 34, and 36 of the beam 28 by determining a centroid of the cross-section and then summing the moments of inertia for each section. For example, with reference to
Ix=IC+Ad2
where IC is the moment of inertia of the section 32 (i.e., I32), the section 34 (i.e., I34), or the section 36 (i.e., I36) about the section's centroid, A is the area of the respective section 32, the section 34, or the section 36, and d is the vertical distance from the respective centroid (not shown) to the neutral axis 62 for each of the section 32, the section 34, or the section 36. Further, where sections 32, 34, 36 are approximated by rectangles then
in which “b” corresponds to the base or width dimension of the rectangle and “h” corresponds to the height dimension of the rectangle.
Considering the sections 32, 34, and 36 as rectangles, and with reference to
Itotal=I32+I34+I36
At a calculated moment of inertia of 0.403, the theoretical capacity of the existing shelf support beam 28 is determined by finite elemental analysis to be 1,734 pounds (786.5 kilograms). Finite elemental analysis was performed on Ansys® workbench software version 15.1 with a static structure analysis module. Pre-processing includes A36 Structural steel as a material assignment and a linear-elastic mechanical property. Meshing was tetrahedron fine mesh. A CAD model of a beam shown in
With reference now to
Further in that regard, the shelf support beam 80 generally consists of a structural member 82 that is formed in a generally C-shaped and having a longitudinal axis 88. The exemplary shelf support beam 80 may be visually sectioned into three parts, i.e., section 84, section 86, and section 90 (see
In that C-shaped cross-sectional configuration, section 84 includes a web 94, which forms a vertical portion of the structural member 82 during use. The section 86 defines a top flange 96 and is configured to receive the shelf 22. The top flange 96 extends generally inwardly in the shelving unit 10 (e.g.,
Section 90 defines a bottom flange 112 that joins the web 94 on an opposite end of the web 94 from the top flange 96. As shown, the web 94 may be radiused at each of the locations at which the structural member 82 transitions to the top flange 96 and to the bottom flange 112. The web 94 is defined in the structural member 82 from a location at which a tangent to the surface curvature of an inner surface of the top flange 96 is parallel to an inner surface of the web 94 at one end to a location at which a tangent to the surface curvature of an inner surface of the bottom flange 112 is parallel to the inner surface of the web 94 at the opposing end. Collectively, the top flange 96, the web 94, and the bottom flange 112 define the channel 92 and a centroid 98, which is spaced apart from each of the top flange 96, the web 94, and the bottom flange 112. By way of example only, the centroid 98 is spaced apart from the nearest portion of the structural member 82 by less than 0.25 inch (0.635 centimeter).
With reference to
(1) a strip width of 5.735 inches (14.57 centimeters) (the strip width of the structural member 82 in the cross-section of
(2) a weight of 6.8 pounds (3.084 kilograms), the weight is an approximation based on the available gage and dimensional variation of the strip from which the beam is made,
(3) a cavity height (C1) (the inside dimension between the top flange 96 at the lower portion 104 and the bottom flange 112) of 2.801 inches (7.115 centimeters),
(4) a gauge of 0.054 inch (0.1372 centimeter),
(5) a top flange width (C2) of 1.278 inches (3.246 centimeters) (as measured from the end 114 to the inwardly facing surface of the web 94),
(6) a bottom flange width (C3) of 1.024 inches (2.601 centimeters) (as measured from the end 116 to the inwardly facing surface of the web 94),
(7) a web height (C4) of 2.927 inches (7.435 centimeters),
(8) an overall height (C5) of 3.314 inches (8.418 centimeters) and
(9) a hardness of 12 on the Webster scale.
The moment of inertia for the beam 80 is calculated for each section of the beam 80 by determining a centroid of each section and then summing the moments of inertia for each section as described above with respect to the shelf support beam 28.
The moment of inertia of the cross-section of the shelf support beam 80 is greater than 0.4, by way of example, it is at least 0.452. As shown in Table 2, the moment of inertia is calculated to be 0.452 or about 12% greater than the beam 28 of
As described above, the dimensions of the shelf support beam 80 are different than the shelf support beam 28 though the strip widths are the same. Despite being of equivalent strip widths, the different dimensions of the shelf support beam 80 produce a greater moment of inertia than the moment of inertia of the shelf support beam 28. By way of comparison, the overall height dimension C5 of the shelf support beam 80 is greater than the overall height dimension A5 of the beam 28 by at least 11% and, by way of further example, the overall height C5 may be greater than 3 inches (7.62 centimeters). In one embodiment, the overall height C5 of the shelf support beam 80 is about 3.30 inches (about 8.382 centimeters) (unless otherwise indicated herein with reference to dimensions “about” means a dimension that is ±0.01 of the stated dimension) (e.g., an exemplary height is 3.314 inches (8.418 centimeters), which is about 3.30 inches (about 8.382 centimeters)). However, the strip width remains the same at 5.735 inches (14.57 centimeters). For equivalent strip widths, the shelf support beam 80 shown in
By way of further comparison, the cavity height C1 of the web 94 is greater than the cavity height A1 of the web 40 (
By comparison, for the shelf support beam 28 of
In one embodiment of the invention, the shelf support beam 80 has a ratio of cavity height to the sum of flange widths of greater than 1. That is, the web height is greater than the sum of the flange widths. Advantageously, the shelf support beam 80 may be produced from the same material stock as the shelf support beam 28 though the shelf support beam 80 is capable of carrying greater loads.
With reference now to
In that C-shaped cross-sectional configuration, section 134 includes a web 144, which forms a vertical portion of the structural member 132 during use. The section 134 defines a top flange 146 and is configured to receive the shelf 22. The top flange 146 extends generally inwardly in the shelving unit 10 (e.g.,
Section 140 defines a bottom flange 162 that joins the web 144 on an opposite end of the web 144 from the top flange 146. As shown, the web 144 may be radiused at each of the locations at which the structural member 132 transitions to the top flange 146 and to the bottom flange 162. The web 144 is defined in the structural member 132 from a location at which a tangent to the surface curvature of an inner surface of the top flange 146 is parallel to an inner surface of the web 144 at one end to a location at which a tangent to the surface curvature of an inner surface of the bottom flange 162 is parallel to the inner surface of the web 144 at the opposing end. Collectively, the top flange 146, the web 144, and the bottom flange 162 define the channel 142 and a centroid 148, which is spaced apart from each of the top flange 146, the web 144, and the bottom flange 162. By way of example, the centroid 148 may be located within 0.25 inch (0.635 centimeter) of the structural member 132 and more particularly the web 144.
With reference to
While the recessed region 164 may decrease the overall height of the shelf support beam 130 (i.e., relative to the shelf support beam 80 shown in
With reference to
With reference to
With reference to
(1) a strip width of 5.735 inches (14.57 centimeters) (the strip width of the structural member 132 in the cross-section of
(2) a weight of 6.8 pounds (3.084 kilograms), the weight is an approximation based on the available gage and dimensional variation of the strip from which the beam is made,
(3) a cavity height (D1) (the inside dimension between the top flange 146 at the lower portion 154 and the bottom flange 162) of 2.688 inches (6.828 centimeters),
(4) a gauge of 0.054 inch (0.1372 centimeter),
(5) a top flange width (D2) of 1.278 inches (3.246 centimeters) (as measured from the end 184 to the inwardly facing surface of the web 144 at 174),
(6) a bottom flange width (D3) of 1.024 inches (2.601 centimeters) (as measured from the end 186 to the inwardly facing surface of the web 144),
(7) a web height (D4) of 2.814 inches (7.148 centimeters),
(8) an overall height (D5) of 3.201 inches (8.131 centimeters),
(9) a hardness of 12 on the Webster scale,
(10) the base surface (D6) measures 1.550 inches (3.937 centimeters) with each of the opposing sidewalls measuring 0.477 inches (1.212 centimeters),
(11) the spaced apart portion (D7) is 0.727 inch (1.847 centimeters), and
(12) the spaced apart portion (D8) is 0.094 inch (0.2388 centimeter).
A moment of inertia for the beam 130 may be calculated for each section of the beam 130 by determining a centroid of each section and then summing the moments of inertia for each section as described above with respect to the shelf support beam 28.
The moment of inertia of the cross-section of the shelf support beam 130 is greater than 0.403. As shown, the moment of inertia is 0.440 or about 9% greater than the moment of inertia of beam 28. As such, the theoretical capacity of the exemplary shelf support beam 130 is believed to be greater than the beam shown in
As described above, the dimensions of the shelf support beam 130 are different than the shelf support beam 28 though the strip widths are the same. Despite being of equivalent strip widths, the different dimensions of the shelf support beam 130 with the recessed region 164 produce a greater moment of inertia than the moment of inertia of the shelf support beam 28.
By way of comparison, the overall height dimension of the shelf support beam 130 is greater than the overall height dimension of the beam 28 by at least 7%. In one embodiment, the overall height D5 of the shelf support beam 130 is about 3.2 inches (about 8.128 centimeters). However, the strip width remains the same at 5.735 inches (14.57 centimeters). For equivalent strip widths, the shelf support beam 130 shown in
By way of further comparison, a cavity height D1 of the web 144 (
With reference now to
In that C-shaped cross-sectional configuration, section 206 includes a web 216, which forms a vertical portion of the structural member 202 during use. The section 210 defines a top flange 220 and is configured to receive the shelf 22. The top flange 220 extends generally inwardly in the shelving unit 10 (e.g.,
Section 212 defines a bottom flange 234 that joins the web 216 on an opposite end of the web 216 from the top flange 220. As shown, the web 216 may be radiused at each of the locations at which the structural member 202 transitions to the top flange 220 and to the bottom flange 234. The web 216 is defined in the structural member 202 from a location at which a tangent to the surface curvature of an inner surface of the top flange 220 is parallel to an inner surface of the web 216 at one end to a location at which a tangent to the surface curvature of an inner surface of the bottom flange 234 is parallel to the inner surface of the web 216 at the opposing end. Collectively, the top flange 220, the web 216, and the bottom flange 234 define the structural member 202 and a centroid 238.
With reference to
While the recessed region 236 may decrease an overall height of the shelf support beam 200 (i.e., relative to the shelf support beam 80 shown in
With reference to
Furthermore, the recessed region 236 need not be symmetrically positioned within the web 216. Although embodiments of the invention are not limited to the spacing shown, in
Exemplary dimensions of the beam 200 shown in
(1) a strip width of 5.735 inches (14.57 centimeters) (the strip width of the structural member 202 in the cross-section of
(2) a weight of 7.4 pounds (3.357 kilograms), the weight is an approximation based on the available gage and dimensional variation of the strip from which the beam is made,
(3) a cavity height (E1) (the inside dimension between the top flange 220 at the lower portion 226 and the bottom flange 234) of 2.723 inches (6.916 centimeters),
(4) a gauge of 0.054 inch (0.1372 centimeter),
(5) a top flange width (E2) of 1.056 inches (2.682 centimeters) (as measured from the end 260 to the inwardly facing surface of the web 216 at 252),
(6) a bottom flange width (E3) of 0.876 inches (2.225 centimeters) (as measured from the end 262 to the inwardly facing surface of the web 216 at 254),
(7) a web height (E4) of 3.159 inches (8.024 centimeters),
(8) an overall height (E5) of 3.347 inches (8.501 centimeters),
(9) a hardness of 12 on the Webster scale,
(10) the base surface width (E6) is 1.550 inches (3.937 centimeters) with each of the opposing sidewalls being 0.477 inches (1.212 centimeters),
(11) the spaced apart portion (E7) is 0.556 inch (1.412 centimeters), and
(12) the spaced apart portion (E8) is 0.083 inch (0.2108 centimeter).
The moment of inertia for the shelf support beam 200 is calculated for each section of the beam 200 by determining a centroid of each section and then summing the moments of inertia for each section as described above with respect to the shelf support beam 28.
The moment of inertia of the cross-section of the shelf support beam 200 is greater than 0.400 and less than 0.500. By way of comparison with beam 28, the moment of inertia of the beam 200 is about 15% greater than the moment of inertia of the beam 28. The theoretical capacity of the exemplary shelf support beam 200 is determined by finite elemental analysis to be 2,566 pounds (1164 kilograms), which is about a 48% increase in theoretical capacity as compared to the shelf support beam 28 of
As described above, the dimensions of the shelf support beam 200 are different than the shelf support beam 28 though the strip widths are the same. Despite being of equivalent strip widths, the different dimensions of the shelf support beam 200 with the recessed region 236 produce a greater moment of inertia than the moment of inertia of the shelf support beam 28. By way of comparison, the moment of inertia of the cross-section of the shelf support beam 28 is 0.403 and the moment of inertia of the cross-section of the shelf support beam 200 is 0.465. Thus, with the same strip width, the moment of inertia increases by 15% by changing the configuration of the cross-section. With regard to the different dimensions, the overall height E5 of the shelf support beam 200 is greater than the overall height A5 of the beam 28 by at least 12%. In one embodiment, the overall height E5 of the shelf support beam 200 is about 3.35 inches (about 8.509 centimeters) (e.g., 3.347). However, the strip width remains the same at 5.735 inches (14.57 centimeters). For equivalent strip widths, the shelf support beam 200 shown in
By way of further comparison, the cavity height E1 of the web 216 (
While the present invention has been illustrated by the description of various embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Thus, the various features discussed herein may be used alone or in any combination. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope of the general inventive concept.
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