AU2011221368A1

AU2011221368A1 - Protector Apparatus

Info

Publication number: AU2011221368A1
Application number: AU2011221368A
Authority: AU
Inventors: John Rayner
Original assignee: APC GROUP Pty Ltd
Current assignee: APC GROUP Pty Ltd
Priority date: 2010-09-10
Filing date: 2011-09-07
Publication date: 2012-03-29
Anticipated expiration: 2031-09-07
Also published as: AU2011221368B2

Abstract

-15 Abstract A protector apparatus 20 for protecting a structural member 51 from being damaged by an impact with an object includes a body 21. The body 21 is formed from a resiliently flexible material and includes a front bumper 22, and a pair of 5 rear side walls 23. The rear side walls 23 extend from the front bumper 22 such that the rear side walls 23 are able to clamp on to the structural member 51. _ -- 23

Description

P/00/011 28/5/91 Regulation 3.2 AUSTRALIA Patents Act 1990 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Name of Applicant: APC Group Pty Ltd Actual Inventor John Rayner Address for service is: WRAYS Ground Floor, 56 Ord Street West Perth WA 6005 Attorney code: WR Invention Title: Protector Apparatus The following statement is a full description of this invention, including the best method of performing it known to me:

I

-2 PROTECTOR APPARATUS Field of the Invention The present invention relates generally to apparatus for protecting 5 structures and structural components or members. Although the present invention will be described with particular reference to protecting rack structures, it will be appreciated that it may be used to protect other types of structures. 10 Background Art Protector apparatus are used for protecting structures or structural components or members from being damaged as a result of collisions with objects. For example, such apparatus are often used to protect storage racks which are used for storing goods in warehouses and the like. Such storage 15 racks typically include a plurality of upright posts which support a plurality of beams which in turn support a plurality of shelves. Vehicles such as forklifts, reach trucks and the like are often used to transfer pallets and/or goods to and from the pallets of such storage racks. The upright posts of the storage racks are susceptible to damage as a result of collisions with the vehicles and/or the 20 pallets and/or goods which they are transferring to or from the shelves. Over the years various types of protector apparatus have been developed. For example, metal guards/protector apparatus which are constructed from steel are either designed to deflect impact loads away from the upright post or the floor slab supporting the post, or they transfer these loads into 25 the upright or the floor slab depending on the way in which the apparatus is attached to the post and/or the slab. Apparatus of this type provide very little impact absorption. They also do not protect the rear of the post which they are supposedly protecting. An example of a metal guard/protector apparatus is the DexionTM Smart 30 GuardiM guard/protector apparatus which is the subject of Australian design registration No. 319547, and published Australian patent application No. 2009200245. Another example is Dematic Pty Ltd's ColbyTM Protect-a-RackTM metal guard/protector apparatus which is disclosed in Australian design registration No. 301237, and Australian innovation patent No. 2009100748.

-3 Plastic guards/protector apparatus typically absorb impacts, but in order to do this effectively they become cumbersome to fit. Also, they tend to intrude into the product storage areas, thereby reducing minimum clearance requirements between unit loads and rack uprights. They also typically provide 5 little or no rear protection for the upright posts they are supposed to protect. An example of a plastic guard/protector is the Eye-Catcher InnovationSTM Protect-ltTM rack protection system/protector apparatus which is the subject of Australian patent No. 2004290611, and which is disclosed in International Patent Publication No. WO 2005/049453. 10 It is against this background that the present invention has been developed. Summary of the Invention It is an object of the present invention to overcome, or at least 15 ameliorate, one or more of the deficiencies of the prior art mentioned above, or to provide the consumer with a useful or commercial choice. Other objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, a preferred 20 embodiment of the present invention is disclosed. According to a first broad aspect of the present invention, there is provided a protector apparatus for protecting a structural member from being damaged by an impact with an object, the apparatus comprising a body including a front bumper, and a pair of rear side walls extending from the front bumper 25 such that the rear side walls are able to clamp on to the structural member, wherein the body is formed from a resiliently flexible material. Preferably, the front bumper and the rear side walls are integrally formed with each other. Preferably, the apparatus is formed by an extruding process. 30 In one preferred form, the whole body is formed from the same resiliently flexible material. Preferably, the resiliently flexible material has a hardness of 75 - 85 Duro. It is preferred that the resiliently flexible material is rubber. Preferably, the rubber is EPDM (ethylene propylene diene monomer) rubber.

-4 In an alternative preferred form, the resiliently flexible material includes a resiliently flexible first material from which at least part of the front bumper is formed, and a resiliently flexible second material from which the rear side walls are formed, wherein the resiliently flexible second material is stiffer or harder 5 than the resiliently flexible first material. Preferably, the resiliently flexible first and second materials are both rubber. It is preferred that the rubber is EPDM rubber. Alternatively, the resiliently flexible first and second materials are both plastic. It is preferred that the plastic is PVC (polyvinyl chloride). Preferably, each resiliently flexible material from which the body is 10 formed is UV stabilised, flame retardant, or recyclable. According to a second broad aspect of the present invention, there is provided a protector apparatus for protecting a structural member from being damaged by an impact with an object, the apparatus comprising a body including a front bumper, the front bumper including a plurality of angled side faces for 15 deflecting the object away from the structural member, and a front face from which the angled side faces extend. Preferably, the body also comprises a pair of rear side walls extending from the front bumper such that the rear side walls do not substantially increase a frontal width of the body. 20 Preferably, the front bumper is substantially hollow and also includes a rear wall, a front wall which includes the front face, a pair of side walls which extend between the rear wall and the front wall and which include the angled side faces. According to a third broad aspect of the present invention, there is 25 provided a protector apparatus for protecting a structural member from being damaged by an impact with an object, the apparatus comprising a body including a pair of rear side walls, each rear side wall including an angled face for deflecting the object away from the structural member, and a rear portion for preventing a rear portion of the structural member from being impacted by the 30 object. Preferably, each rear side wall also includes a ridge for insertion into a channel in a side wall of the structural member. Preferably, each rear side wall also includes an intermediate portion from which the rear portion of the side wall extends. It is preferred that the -5 intermediate portion includes the angled face of the rear side wall. It is also preferred that the intermediate portion includes the ridge of the rear side wall. Preferably, each rear side wall also includes a front portion from which the intermediate portion of the rear side wall extends. 5 Preferably, the body also includes a front bumper from which the rear side walls extend, the front bumper including a ridge for engaging with a front wall of the structural member. According to a fourth broad aspect of the present invention, there is provided a protector apparatus for protecting a structural member from being 10 damaged by an impact with an object, the apparatus comprising a body including a front bumper, and a pair of rear side walls extending from the front bumper such that the rear side walls are able to clamp on to the structural member. According to a fifth broad aspect of the present invention, there is provided an assembly comprising a protector apparatus according to any one of 15 the first, second, and third broad aspects of the present invention, and a structural member to which the protector apparatus is secured. According to a sixth broad aspect of the present invention, there is provided a method for protecting a structural member, the method comprising the steps of: 20 providing a protector apparatus according to any one of the first, second, third, or fourth broad aspects of the present invention; and securing the protector apparatus to the structural member. Brief Description of the Drawings 25 In order that the invention may be more fully understood and put into practice, a preferred embodiment thereof will now be described with reference to the accompanying drawings, in which: Figure 1 is a front perspective view of a preferred embodiment of a protector apparatus; 30 Figure 2 is a rear perspective view of the protector apparatus depicted in figure 1; Figure 3 is a front perspective view of an assembly including the protector apparatus depicted in figures 1 and 2 secured to a first type of upright post; -6 Figure 4 is a plan view of the assembly depicted in figure 3; Figure 5 is a front perspective view of an assembly including the protector apparatus depicted in figures 1 and 2 secured to a second type of upright post; 5 Figure 6 is a front perspective view of another preferred embodiment of a protector apparatus; and Figure 7 is a rear perspective view of the protector apparatus depicted in figure 6. 10 Best Mode(s) for Carrying out the Invention In the drawings, like features of the various embodiments have been referenced with like reference numbers. Referring to figures 1 and 2, there is depicted a protector apparatus 20 for protecting a structural member from being damaged by an impact with an 15 object. Apparatus 20 includes an elongate body 21 which includes a front bumper 22 for absorbing frontal impacts, and a pair of rear side walls 23 which extend from, and which are integrally formed with the front bumper 22. Front bumper 22 has a hollow profile which has a trapezoidal shape. 20 The trapezoidal shaped profile of the front bumper 22 is optimised so that the front bumper 22 is able to absorb impacts with objects. A rear wall 30 of the front bumper 22 includes a central ridge 31 for engaging with a front wall of the structural member which is protected by the apparatus 20. 25 A front wall 32 of the front bumper 22 is spaced apart from the rear wall 30 and includes a front face/surface 33. Front bumper 22 also includes a pair of side walls 34 extending between the rear wall 30 and the front wall 32 of the front bumper 22. Each side wall 34 includes an angled or inclined side face/surface 35 for deflecting objects away 30 from the structural member which is protected by the apparatus 20. Each of the rear side walls 23 includes a front portion 40, an intermediate portion 41 which extends from the front portion 40, and a rear portion 42 which extends from the intermediate portion 41. Each intermediate portion 41 includes an angled or inclined outer -7 face/surface 43 for deflecting objects away from the structural member which is protected by the apparatus 20, a ridge 44 for insertion into a channel in a side wall of the structural member, and an angled or inclined inner face/surface 45 for contacting the structural member side wall so that the rear side walls 23 are able 5 to clamp on to the structural member. The rear portions 42 of the rear side walls 23 are able to prevent a rear portion of the structural member which is protected by the apparatus 20 from being impacted and damaged by objects In one preferred form, the whole body 21 is formed from the same 10 resiliently flexible material. For example, the whole body 21 may be formed from EPDM (ethylene propylene diene monomer) rubber that has a hardness of 75 85 Duro. EPDM is a resilient rubber that is chlorine free and that is capable of withstanding temperatures up to 120 *C and down to -40 C* without its performance being affected. 15 In an alternative preferred form, at least the front wall 32 and the side walls 34 of the front bumper 22 are formed from a resiliently flexible first material, and the rear side walls 23 are formed from a resiliently flexible second material which is stiffer or harder than the first material. For example, the first material and the second material may be a rubber or plastic material, and the rubber or 20 plastic which the front bumper 22 is formed from may be a softer grade of rubber or plastic compared to the rubber or plastic which the rear side walls 23 are formed from. If the first and second materials are rubber materials, it is preferred that the first and second materials are both EPDM (ethylene propylene diene 25 monomer) rubber of differing stiffness or hardness. Alternatively, if the first and second materials are plastic materials, it is preferred that the first and second materials are both PVC (polyvinyl chloride) of differing stiffness or hardness. Forming the front bumper 22 from the more flexible first material rather than the second material provides the front bumper 22 with superior impact 30 absorption and shape retention properties. On the other hand, forming the rear side walls 23 from the second material rather than the first material increases the clamping effect of the rear side walls 23 on the structural member which is protected by the apparatus 20 so that the apparatus 20 is able to be more securely clamped to the structural -8 member. Although stiffer than the first material, the second material is still flexible enough to be able to absorb an impact between an object and one or both of the rear side walls 23. The mechanical properties of rubber (e.g. EPDM rubber) are such that, 5 compared to many other materials, it can take or withstand a greater amount of strain before failure. This implies that rubber is able to provide a greater amount of impact energy absorption. Rubber is also very elastic and cannot be permanently deformed unless its elastic limit, which is far higher than many other materials, is exceeded. In addition, rubber has good damping properties, and is 10 consequently able to dissipate impact energy better than many other materials. Irrespective of the material or materials that the body 21 is formed from, it is preferred that the material(s) is/are UV stabilised, flame retardant, and recyclable. Apparatus 20 is formed using an extruding process which enables the 15 apparatus 20 to be extruded to any required length. Referring to figures 3 and 4, an assembly 50 includes the protector apparatus 20 secured to a structural member in the form of an upright post 51 for a rack or other structure. Post 51 includes a front wall 52 which includes a central channel 53, and 20 a plurality of openings 54. Channel 53 functions as a web-stiffener which stiffens/increases the rigidity of the front wall 52. A pair of side walls 55 extends from the front wall 52. Each side wall 55 includes a front portion 56, a channel 57, a plurality of openings 58 which are located at the bottom of the channel 57, and a rear flange 59 which includes an 25 edge 60. Apparatus 20 is secured to the post 51 by locating the rear side walls 23 of the apparatus 20 adjacent to the sides of the post 51 so that the front wall 52 of the post 51 is substantially located between the rear side walls 23. The apparatus 20 is then pressed or otherwise forced against the post 51 so that the 30 rear side walls 23 spread apart from each other sufficiently to allow the post 51 to enter the space or channel between the side walls 23. Apparatus 20 is pressed or otherwise forced against the post 51 until the ridges 44 of the apparatus 20 are located in the channels 57 and until the ridge 31 locates in the channel 53 and thereby engages with the front wall 52.

-9 The inner faces 45 of the rear side walls 23 press against and grip on to the edges 60 of the post side walls 55 so that the post 51 is clamped between the rear side walls 23. The clamping action of the rear side walls 23 also assists in centralising the apparatus 20 relative to the post 51. 5 The rear portions 42 of the rear side walls 23 extend behind or wrap around the rear flanges 59 of the post 51 so that they are able to prevent an object such as a pallet, for example, from impacting and damaging the rear flanges 59 as the pallet is being removed from the rack or other structure which the post 51 may be part of. 10 The angled faces 43 of the rear side walls 23 are able to deflect an object such as a pallet, for example, away from the apparatus 20 and the post 51 as the pallet is being removed/transferred from the rack or other structure which the post 51 may be part of. Locating the ridge 31 in the channel 53 of the post 51 centralises the 15 apparatus 20 relative to the post 51. This enables the apparatus 20 to be centralised relative to the post 51 even if the width of the front wall 52 of the post 51 differs from that shown. The angled or inclined side faces 35 of the apparatus 20 are able to assist in guiding or directing an object such as a pallet, for example, which is 20 being inserted into or removed from the rack or other structure which the post 51 is part of. The angled or inclined side faces 35 also allow for easier access in that they allow the pallet to be inserted into or removed from the rack or other structure at an angle. Figure 5 depicts an assembly 70 which is identical to the assembly 50 25 except that it includes an upright post 71 rather than the upright post 51 of the assembly 50. Post 71 is identical to the post 51 except that the front wall 52 of the post 71 does not include the channel 53 of the post 51. Consequently, the ridge 31 of the apparatus 20 is unable to centralise the apparatus 20 relative to the post 71. 30 Apparatus 20 may also be secured to a large range of other posts whose profiles are different to the posts depicted in the drawings. For example, apparatus 20 may be secured to a post which is configured such that the ridges 44 of the apparatus 20 contact or grip the post. The ridges 44 assist in allowing the apparatus 20 to be fitted to posts having a variety of different profiles.

- 10 The rear side walls 23 of the apparatus 20 are able to protect the side walls 55 of the post 51 while minimising 'clear entry' obstruction to an object such as a pallet, for example, which is being inserted or removed from the rack or other structure which the post 51 may form part of. The reason for this is that the 5 rear side walls 23 do not increase the frontal width of the body 21 because they do not project out beyond the frontal width of the front bumper 22. Apparatus 20 can easily be modified to suit applications where the post which the apparatus 20 is secured to is part of a structure such as a rack which also includes a bottom beam or other component which presents an obstruction 10 to the apparatus 20. To avoid fouling between the apparatus 20 and the bottom beam or other component, the apparatus 20 can be modified to negotiate/by pass such an obstruction by cutting one or more portions from one or both rear side walls 23 so as to form one or more cut outs which are able to receive the obstruction. 15 Referring to figures 6 and 7, there is depicted a protector apparatus 80 for protecting a structural member such as the upright post 51 or 71 from being damaged by an impact with an object. Apparatus 80 is identical to the apparatus 20 except that the front portion 40 of each rear side wall 23 of the apparatus 80 includes a longitudinally 20 extending opening 81 and the front portion 40 bows outwardly slightly so as to increase the impact-absorbing/cushioning that is able to be provided by the rear side walls 23 against impacts with objects such as, for example, pallets. An advantage of the apparatus 50, 80 over prior-art metal guards/protector apparatus is that they are more impact-absorbing which means 25 less transfer of impact load onto the structural member, such as an upright post, which is being protected or the floor which supports the structural member. In addition, the apparatus 50, 80 are able to provide better rear and side protection compared to prior-art metal guards/protector apparatus. The apparatus 50, 80 are also more compact compared to prior-art 30 plastic guards/protector apparatus. This allows for greater clearances between unit loads and rack uprights. Furthermore, the wraparound design of the apparatus 50, 80 means that they are able to provide better rear protection for a structural member compared to prior-art plastic guards/protector apparatus.

-11 It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing from the spirit and scope thereof. The variations and modifications as would be apparent to persons skilled in the art are deemed to fall within the broad scope 5 and ambit of the invention as herein set forth. Throughout the specification and claims, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. 10 Throughout the specification and claims, unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms. It will be clearly understood that, if a prior art publication is referred to herein, that reference does not constitute an admission that the publication forms 15 part of the common general knowledge in the art in Australia or in any other country.

Claims

1. A protector apparatus for protecting a structural member from being damaged by an impact with an object, the apparatus comprising a body including a front bumper, and a pair of rear side walls extending from the front bumper 5 such that the rear side walls are able to clamp on to the structural member, wherein the body is formed from a resiliently flexible material.

2. The protector apparatus of claim 1, wherein the front bumper and the rear side walls are integrally formed with each other.

3. The protector apparatus of any one of the preceding claims, wherein the 10 apparatus is formed by an extruding process.

4. The protector apparatus of any one of the preceding claims, wherein the whole body is formed from the same resiliently flexible material.

5. The protector apparatus of claim 4, wherein the resiliently flexible material has a hardness of 75 - 85 Duro. 15

6. The protector apparatus of claim 4 or 5, wherein the resiliently flexible material is rubber.

7. The protector apparatus of claim 6, wherein the rubber is EPDM rubber.

8. The protector apparatus of any one of claims 1 to 3, wherein the resiliently flexible material includes a resiliently flexible first material from which 20 at least part of the front bumper is formed, and a resiliently flexible second material from which the rear side walls are formed, wherein the resiliently flexible second material is stiffer or harder than the resiliently flexible first material.

9. The protector apparatus of claim 8, wherein the resiliently flexible first and second materials are both rubber. 25

10. The protector apparatus of claim 9, wherein the rubber is EPDM rubber.

11. The protector apparatus of claim 8, wherein the resiliently flexible first and second materials are both plastic.

12. The protector apparatus of claim 11, wherein the plastic is PVC.

13. The protector apparatus of any one of the preceding claims, wherein 30 each resiliently flexible material is UV stabilised, flame retardant, or recyclable.

14. A protector apparatus for protecting a structural member from being damaged by an impact with an object, the apparatus comprising a body including a front bumper, the front bumper including a plurality of angled side faces for - 13 deflecting the object away from the structural member, and a front face from which the angled side faces extend.

15. The protector apparatus of claim 14, wherein the body also comprises a pair of rear side walls extending from the front bumper such that the rear side 5 walls do not substantially increase a frontal width of the body.

16. The protector apparatus of claim 14 or 15, wherein the front bumper is substantially hollow and also includes a rear wall, a front wall which includes the front face, a pair of side walls which extend between the rear wall and the front wall and which include the angled side faces. 10

17. A protector apparatus for protecting a structural member from being damaged by an impact with an object, the apparatus comprising a body including a pair of rear side walls, each rear side wall including an angled face for deflecting the object away from the structural member, and a rear portion for preventing a rear portion of the structural member from being impacted by the 15 object.

18. The protector apparatus of claim 17, wherein each rear side wall also includes a ridge for insertion into a channel in a side wall of the structural member.

19. The protector apparatus of claim 17 or 18, wherein each rear side wall 20 also includes an intermediate portion from which the rear portion of the side wall extends.

20. The protector apparatus of claim 19, wherein the intermediate portion includes the angled face of the rear side wall.

21. The protector apparatus of claim 19 or 20, wherein the intermediate 25 portion includes the ridge of the rear side wall.

22. The protector apparatus of any one of claims 19 to 21, wherein each rear side wall also includes a front portion from which the intermediate portion of the rear wall extends.

23. The protector apparatus of any one of claims 17 to 22, wherein the body 30 also includes a front bumper from which the rear side walls extend, the front bumper including a ridge for engaging with a front wall of the structural member.

24. A protector apparatus for protecting a structural member from being damaged by an impact with an object, the apparatus comprising a body including - 14 a front bumper, and a pair of rear side walls extending from the front bumper such that the rear side walls are able to clamp on to the structural member.

25. An assembly comprising a protector apparatus according to any one of claims 1 to 24, and a structural member to which the protector apparatus is 5 secured.

26. A method for protecting a structural member, the method comprising the steps of: providing a protector apparatus according to any one of claims 1 to 24; and 10 securing the protector apparatus to the structural member.

27. A protector apparatus substantially as hereinbefore described with reference to: figures 1 to 5; or figures 6 and 7.

28. An assembly substantially as hereinbefore described with reference to: figures 1 to 4; figures 1, 2, 4, and 5; or figures 6 and 7. 15

29. A method for protecting a structural member, the method being substantially as hereinbefore described with reference to: figures 1 to 4; figures 1, 2, 4, and 5; or figures 6 and 7.