NZ230840A

NZ230840A - Support member for use as construction beam or pallet component; method of fabrication

Info

Publication number: NZ230840A
Application number: NZ230840A
Authority: NZ
Inventors: John Silady
Original assignee: John Silady
Priority date: 1988-10-07
Filing date: 1989-09-29
Publication date: 1992-03-26
Also published as: WO1990003921A1

Description

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Compter* Opacification Filed: Class: Publication Date: 2 e.MAR.jeae.

P.O. Journal, No: V No.: Date: NEW ZEALAND PATENTS ACT. J 953 COMPLETE SPECIFICATION SUPPORT MEMBER l/>fe, JOHN SILADY, of 6 Farhall Place, Glenhaven, New South Wales, 2154, Australia, an Australian citizen hereby declare the invention for which I / we"pray that a patent may be granted to me/us, and the method by which it is to be performed, to be particularly described in and by the following statement: - (followed by page la) 2308 40 - ia- .Xifelc: GUPPOffT MFMRER Field of the Invention The present invention relates to a support member, intended for use as a member or bearer for a pallet of the type commonly used in industry to transport and store loads. However, scaled up support members according to the invention are suitable for use as construction beams, such as roof trusses or floor support joists.

The invention will hereinafter be described with particular reference to support members for pallets but is not restricted to that use.

Background Art In the past pallets have been made from wood.

Wooden pallets, however, suffer from certain disadvantages such as being relatively heavy for their load-bearing capacity. Also they require special treatment if they are to be used for overseas transport or in "clean" environments. The strapping of goods onto timber pallets has also presented problems, as the tines or forks of lifting equipment frequently damage or even break the straps.

In an attempt to overcome some of these problems associated with wooden pallets it has been proposed to make pallets from steel or aluminium, or like materials. Several metal pallets have been proposed, but have been less than satisfactory since they have involved a relatively large number of components in order to provide a satisfactory load-bearing capacity and satisfactory resistance to torsional forces.

In a similar way, support beams used in the construction industry both of wood and metal types have been relatively heavy and correspondingly expensive.

It is an object of the present invention to provide a structural support member which could serve as a pallet member for a pallet, which overcomes or at least ameliorates one or more of the disadvantages of the prior art.

Disclosure of the Invention Accordingly the present invention consists in a support member comprising an elongate channel having a base and two spaced apart side panels, each side panel extending upwardly from the base and having a plurality of integrally formed ribs extending from, or from adjacent the base to the flange, the flange extending tangentially to a curved run out portion of the ribs. 23 0 8 4 Preferably the ribs formed in the channel are indented inwardly.

Preferably also the support member includes a top panel fixedly secured to the channel in planar contact with the flanges.

Brief Description of the drawings Several embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, wherein:- Figure 1 is a perspective view of a structural support member according to the first embodiment of this invention.

Figure 2 is an end elevation of the embodiment in Figure 1.

Figure 3 is a perspective view of a support member according to a second embodiment.

Figure 4 is an end elevation of the embodiment of Figure 3.

Figure 5 is a perspective view of a support member according to a third embodiment of this invention.

Figure 6 is an end elevation of the embodiment in Figure 5.

Figure 7 is a perspective view of a support member according to a fourth embodiment of this invention.

Figure 8 is an end elevation of the embodiment in Figure 7.

Figure 9 is an exploded view of detail 9 of Figure 8. 2308 AO - 4 Figure 10 is a perspective view of a support member according to a fifth embodiment of this invention.

Figure 11 is an end elevation of the embodiment in Figure 10.

Figure 12 is a perspective view of a support member according to a sixth embodiment of this invention.

Figure 13 is an end elevation of the embodiment in Figure 12.

Figure 14 is an exploded part view end elevation of a flange and top assembly of a support member according to a seventh embodiment of this invention, as shown in detail 14 of figures 11 and 13.

Figure 15 is an exploded part view end elevation of a flange and top assembly of a support member according to an eighth embodiment of this invention.

Figure 16 is a perspective view of a decking member of a pallet for connection to a support member according to a ninth embodiment of this invention.

Figure 17 is a perspective view of first variation of a decking member of a pallet for connection to a support member according to the ninth embodiment of this invention.

Figure 18 is a perspective view of a second variation of a decking member of a pallet for connection to a support member according to a ninth embodiment of this invention. 2308 40 Figure 19 is a plan view of several arrangements of decking members on support members in the formation of pallets according to a ninth embodiment of this invention.

Figure 20 is a partial side elevation of a pallet according to a ninth embodiment of this invention.

Figure 21 is a partial side elevation of a pallet according to a ninth embodiment of this invention shown at right angles to the view in Figure 20.

Embodiments of the Invention Turning now to describe the first embodiment of this invention as illustrated in Figure 1 and Figure 2, there is shown a support member indicated generally at 1. The support member 1 comprises an elongate channel 2 having a base 3 and two spaced apart side panels 4, the channel having a generally 'U* shaped cross-section. Throughout the specification the terms horizontal and lateral will correspond to the planar direction defined by the base 3 of a 'U' and similarly the term vertical will correspond with the direction of the upwardly extending arms of a 'U'. It will be appreciated that whilst all embodiments of this invention will be described in this orientation, the terms are used purely to define the relative positions of the elements comprising the invention, and that the invention is not limited to any particular orientation.

Each side panel 4, extends vertically upwards from 23 0 8 4 0 base 3 terminating in an outwardly directed horizontal flange 5. Ribs 6 are pressed into the support member at regular intervals along its length in order to increase its stiffness.

Ribs 6 are pressed upwards into base 3, inwards into side panels 4, and downwards into the flanges 5 on their inner edge. The ribs 6 are wider at the bottom of the arms of the 'U' where they meet the base 3 than they are at the top where the arms meet the flanges 5, and ribs 6 taper uniformly as they rise up side panels 4.

Accordingly the ribs 6 may be conveniently pressed into the support member 1 by a suitable tool having two cooperating parts, the first which is pressed up the side panels 4 of the 'U' and into the base 3, and the second of which is pressed down onto the inner edges of the flanges 5. The parts of the two co-operate with each other in order to press the ribs into the support member and are shaped so as to be easily released after the.pressing action has taken place.

In the regions where the flanges 5 meet the top of the side panels 4 of the 'U' the profile of the rib 6 changes from being inwardly pressed to being outwardly pressed. It should be appreciated that this embodiment of the support member may include a number of variations, for instance the flanges 5 may extend inwardly rather than outwardly and is also possible that the flanges could both extend in the same direction, 2308 4 0 with one extending inwardly and the other extending outwardly.

The flanges 5 may be created when the support member 1 is fabricated or they may be formed afterwards by bending the upper ends of the arms of the 'U'. Alternatively separate flanges may be welded to the upper ends of the arms of the 'U'.

The method of construction of this embodiment will vary to some extent according to size. Where the support members are for use as bearers in the construction of pallets, the channel, complete with flanges can be produced in one single press operation.

For structural beams of varying lengths, the sheet metal is first roll-formed into a 'U' section channel and the ribs are then pressed into the section twenty ribs at a time as a second stage operation.

Typically the dimensions of the construction beams are as follows: WIDTH HEIGHT 50 X 75 50 X 100 75 X 150 75 X 200 75 X 250 75 X 300 100 X 400 (where WIDTH = flange edge to flange edge and typical 230840 - a - flange width = 14mm).

The ribs have a pitch of 30mm, and taper in width from 15mm at the base to 10mm at the top. The metal thickness is between 0.3 and 1.2mm.

In the following descriptions of further embodiments of this invention all common parts are identified by corresponding numerals.

Another embodiment of the invention is shown in Figure 3 and Figure 4. In order to increase the height and stiffness of the support member 1, it is possible to connect two of the channels 2 as shown. The connection is made between the bases 3 of each support member 1 to create an 'H' shaped cross-section support member shown generally at 7. The connection between the channels 2 can be made by means of welds, rivets, adhesive or any other suitable form of connection. However, in a preferred form the connection is made by means of cylindrical extensions from the base of one of the 'U' shaped support members which engage in corresponding holes in the base 3 of the other 'U' shaped support member 1 and are then hammered down to connect the members in the same way as if they were connected by rivets.

Referring now to Figures 5 and 6 there is shown another embodiment of the invention comprising a fabricated channel 2 to which is fixed a top panel 8.

The channel comprises two vertical side panels 4, each 23 0 8 4 0 having a series of inwardly indented ribs 6 and each having two outwardly directed flanges one at the base of the panel and one at the top of the panel. The run out 9 of the ribs 6 extends right up to the flange to give maximum strength and rigidity when connected to the base 3, and top 8 respectively. In this embodiment the base 3 and top 8 are connected to the side panels 4 by a single fold of the top panel 8 and base 3 about the flanges 5 of the side panels 4.

In fabricating the support member 1 the side panels 4 are made from flat sheets of metal, preferably steel or aluminium, by pressing or roll forming a series of vertical ribs 6 all along the length of each side panel 4. The ribs 6 extend from near the top to near the bottom of the side panel. Then, the top and bottom part of each side panel are bent around to form horizontally extending flanges 5. It is important that the vertical ribs extend right up to the point at which the flanges are bent and that the flange extends as a continuation of the run out curve 9 of each rib 6 to maximise the strength of the construction. In this and all fabricated embodiments of the channel, the ribs are parallel and about 15mm in width. The top panel 8 and base 3 are also made from flat sheets of metal. The two side panels 4 are then placed side by side with the flanges 5 extending outwardly and the top section and base 3 are then moved into place such that they extend beyond the flanges 5 of 22 ?8 the side panels 4. The outer ends 10 of the top panel 8 and base 3 are then bent around the horizontally-extending flanges 5 to sandwich them and create a rigid structure. If desired the folded end of the base 3 and top panel 8 may be crimped or spot welded onto the flanges 5 to ensure a rigid fix.

With reference to figures 7, 8 and 9 there is shown a fourth embodiment of the invention. Parts of the figures 7, 8 and 9 corresponding to parts of figures 5 and 6 are identified by corresponding numerals. The fourth embodiment differs from the third embodiment in two important respects, most clearly shown in Figure 9. One difference is that the top panel 8 and base 3 (instead of being bent around horizontal flanges 5 to give three thicknesses of metal as in Figure 5 and Figure 6) are folded together as shown in Figure 9 with flange 5 to give a join in which three thicknesses of the top panel 8 or base 3 are joined with two thicknesses of the horizontal flange 5.

If the horizontal extending flange of the embodiment of Figure 5 has a width of 'W' then the corresponding part of the embodiment of Figure 7 has a width of approximately 2W and the top panel 8 and base 3 overhangs horizontal flange 5 to outer end 10 by a further width of almost 'W' prior to folding. The join of Figure 9 is then formed e.g. by roll forming. * 12 * S A A second difference is that the top panel 8 and base 3 are provided with longitudinally extending ribs 11 and 12 along their length. In the illustrated embodiment the ribs 11 are of 'V' cross-section and indented. The two outer ribs adjacent the side panels 4 are closely adjacent the interior side of the vertical ribs 6 and as such assist in centering the top panel 8 and base 3 with respect to the side panels 4 during assembly wedging the side panels 4 with the flanges 5 against the outer ribs 12, as well as stiffening the top and base panels.

The longitudinally extending ribs 11 and 12 are formed in the base 3 and top panel 8 prior to assembly with side panels 4.

The structural support members described in this embodiment resist twisting and can withstand higher pressures at thinner metal thicknesses than for example 'C' section purloins.

For example a support member for use in a pallet may be made using 0.45mm or thinner high tensile galvanised steel (or zinc alum G 300) for the top panel 8 and base 3 and 0.55mm thickness or less for the side panels 4.

Referring now to figures 10 and 11 there is shown a fifth embodiment of this invention. The construction of the channel is almost identical to that discussed in the first embodiment of this invention referred to in figures 1 and 2. The major difference in the construction of the channel 2 is that the section is generally of a 'V* *2 ^ shaped construction having a very narrow integral base 3 from which the side panels 4 extended in an upwardly and outwardly direction. In this embodiment the ribs 6 are of constant width. As in figures 5 to 9 inclusive the run out 9 of the ribs extends up to the flange. In this embodiment the top panel 8 has two outer longitudinally extending ribs 12 of a substantially 'V' shaped section, the 'V' comprising two curved portions corresponding to the curve of the run out 9, located so that on assembly the two ribs are disposed in supporting engagement with the innermost surfaces of the channel ribs 6. The top panel 8 is connected to the channel 2 by the same method as described in discussion of the fourth embodiment with reference to Figure 9, excepting that the corresponding curves of the longitudinally extending ribs of the top panel 8 provide a more positive support with the ribs 6 of channel 2 (see Figure 14).

The sixth embodiment as illustrated in figures 12 and 13 is almost identical in the method of construction to the fifth embodiment discussed in reference to figures and 11. The major difference is that the shape of the 'U' channel 2 includes a base portion 3 of width greater than discussed in the fifth embodiment but narrower than the width of top panel 8. This embodiment of the invention has an additional longitudinally extending rib 11 midway along its width. The method of attachment of 23 0 8 the channel 'U' to the top panel 8 is as described in the fifth embodiment and shown in more detail in Figure 14.

Figure 15 shows an alternate method of attachment and folding of the top panel 8 with the channel 2, according to an eighth embodiment. As shown the embodiment includes a top panel 8 incorporating longitudinally extending ribs 12 of the same section as described in embodiments 5 and 6. However, it will be appreciated that this method of attachment can be applied to any of the embodiments discussed.

It is highly desirable that the ribs extend fully to the flanges. As illustrated in particular in Figure 6, and again in more detail in figures 9, 14 and 15, the indented ribs 6 terminate at each end in a curved run out portion 9. The outer surface of this portion extends tangentially as a continuation of the curve to form the flange 5. All subsequent folds of the flange with a top panel 8 or bottom panel 3 are precisely nested in a spiral formation against the corner of panel 4. This provides an exceptionally strong fold that will resist buckling.

In this embodiment the top panel 8 and flanges 5 are extended by an additional width 'W' which is folded against the side panels 4 thereby increasing the rigidity at the join. 23 08 4 0 Referring finally to figures 16 to 21 there is shown a ninth embodiment of the invention in which the support members 1 are used as bearers for a pallet. The support members used as bearers are of the type described in the first embodiment and referred to in figures 1 and 2.

Referring now to Figure 16 decking member 14 has a generally 'PT shaped cross-section comprising vertical outer legs 15 joined at their tops to inwardly extending horizontal webs 16 which are joined at their inner ends to the tops of inclined webs 17 which define a central 'V' portion of the 'M'. The lower ends of each of outer legs 15 are bent or formed inwards to form horizontal flanges 18, the lower surfaces of flanges 18 being co-planar with the lower surface of the extremity, or in this case approximately 19, of the 'V' portion 20.

Referring now to Figure 17 the same reference numerals will be used where appropriate to refer to the corresponding elements of Figure 16. The cross-section of decking member 14' is identical to decking member 14 except that the central 'V' portion 20 has a flattened extremity with a horizontal portion 21 joining the lower ends of inclined portions 17. The lower surface of the flattened extremity of the 'V' portion, that is the underside of portion 21, being co-planar with the lower surfaces of flanges 18.

Figure 18 shows a further embodiment in which flanges 18 are turned outwards rather than inwards to 23 0 8 4 0 form a decking member 14 which has outwardly extending flanges 18 the lower surfaces of which are co-planar with the lower surface of the apex 19 of the central 'V' portion 20. It should of course be appreciated that the decking member may be embodied in other forms as well, for instance the Figure 17 embodiment could be formed with the flanges extending outwardly rather than inwardly. It is also possible that the flanges could both extend in the same direction, with one extending inwardly and the other extending outwardly.

The flanges 18 may be created when the decking member is fabricated, or they may be formed afterwards by bending the lower ends of the legs of the M.

Alternatively separate flanges may be welded to ends of the legs of the M. It is not important fabrication technique is adopted, the essential this aspect of the invention being the shape of section which results.

It should also be appreciated that although this aspect of the invention has been described with reference to particular examples where the legs of the 'M' have been vertical and the flanges and webs horizontal this need not be the case and the legs may be offset from the vertical and the flanges and webs offset from the horizontal. Nevertheless it is preferred that the webs the lower which part of the one 23 0 8 16 have co-planar upper surfaces since this is r-v essentially the surface upon which, in a pallet, the load rests.

It is essential that the lowermost points of the lower surfaces of the flanges 18 are co-planar, but it is not necessary that the lower surfaces of the flanges 18 are flat, and they could for instance be rippled or corrugated.

Turning now to Figure 20, various decking members 14 and 14' embodying the first aspect of the present invention are shown attached to a support member 1. The support member 1 defines a flat horizontal support surface 22. The decking members 14 and 14' lie against, and generally transverse support member 1 such that the lower surfaces of flanges 18 and the extremity of the 'V' portion 19 lie against support surface 22. The decking v: members 14 and 14' being attached to support member 1 by means of welds 23 at the contacting portions.

A pallet embodying the third aspect of the present invention may be constructed from two or more spaced apart support members 1 interconnected by two or more decking members 14 as indicated.

In an assembled pallet the upper surfaces of flanges 5 are attached to the lower surfaces of flanges 18 and apex 20 or flattened extremity 21 of the decking members. This is illustrated in figures 20 and 21. 23 08 4 0 Five complete pallets 24 are shown in Figure 19. It can be seen that six welds 25 interconnect each decking member 14 with each support member 1 thus giving a very strong and rigid connection between them. The connection between the support members and the decking members may be a weld as indicated, although it would be appreciated that the connection may be equally well achieved by means of rivetting, screwing or similar mechanical processes.

When made from hi-ten galvanized steel or stainless steel a pallet of adequate strength may be fabricated from material having a thickness between 0.55 to 1.00mm.

When made from aluminium a thickness of 1 to 2mm is required. Alternatively plastics material can be used to fabricate the decking and support members. The height of the return of the deck may vary between 20mm to 10mm depending on the application.

Also while the 'V' section is shown centrally located along the decking members it can be offset to one side or the other if desired. The section of the decking member need not be constant along its entire length but may of course vary along that length provided the required 'M' shaped section is available at the points of contact with the support members.

Additional stiffness can be obtained by the connection of additional decking members to the support member; these additional decking members may be connected 23 0 8 to the top of the support members or to the bottom such that the lower surfaces of the flanges 18 and extremity of the 'V' portion 20 are connected to the underside of base 3. Figures 5 and 6 show one such additional decking member 24. This sandwiching of the support members by decking members increases the rigidity of the resulting pallet.

A pallet having additional height can be obtained by substituting the single *U' shaped support member shown in Figure 1 for the double 'U' shaped support member shown in figures 3 and 4.

As will be apparent to those skilled in the art from the teaching hereof, the features of one embodiment can be combined with those of another to produce other embodiments within the scope of the invention.

Claims

n o * -.-J ''' -j 0 8 0 • 19 - WHAT I CLAIM IS;

1. A "support member comprisiru; an e 1 uiiriite channel ha*, ing a base arid two spaced apart side panels. each side panel ox tend i ri^ upwardly from the has*.' and having a laterally ex t end i n^. fUtn^o a * its upper edge remote from the base. and huvin.^ a plurality of integrally formed ribs ox* und ins from, or from adjacent tho base, to the flan.ce. the fiance e \ t end i nc tangent ial ly to a curvcd run out portion of the rib--,.

2. A support member a;: claimed in Claim 1 wherein the base of the channel is sufficiently narrow to define a 'liannol of genera 11 y "V shaped cross sec t i on.

3 A support member as claimed iri Claim I or Claim 2 in which the ribs are i nde n t r- d i i nv.i rd 1 y .

4. A support member as claimed in Claim 1 or Claim 3 in which the channel is assembled from two side panels and one ba:;o panel,

5. A support member as claimed in any one of the preceding claims including a substantially planar top panel fixedly secured to the channel in planar contact with the flanges.

6. A support, member according to Claim 5 wherein the mectns by which the top panel is secured to the side panel'; includes a folded connection of the top panel and the flanges.

~. A support member according to Claim 4 wherein the means by which the base panel is secured to the side panels includes a folded interconnec t ion of the base panel and the fiances.

8. A support member as claimed in Claim 5 wherein the top panel includes at least one longitudinally extending: indentation of substantially "V shaped cross-section. SO JAN 5992 5 0 8 0 i;o

A support member as claimed in Claim 7 or Claim 3 wherein the base panel includes at least one longitudinal ly extending indentation of substantially 'V shaped cross-seetion.

10. A support member according to Claim 8 or Claim 9 including a longitudinally extending indentation extending adjacent to and internally of each side pane1.

11 . A support member according' to Claim 10 wherein the cross-sec'ion of each longitudinally extending indentation extending adjaeent to and internal of each side wall corresponds with and is in mutual supportive aligrjnent with the run out portion of the rib adjacent th-> flange.

12. A support m.'mb'-r comprising two ch.uui.'l m«.-mbers .->ach a., cording tu Any one of the pre<. eding claim:: having 11».- t>.i;.- . f one joined to the base Of the other in overlaying re 1 a t iorish i i>.

13. A pallet comprising; a siippjrt member as claimed in any one of th.--preceding' claims in combination with one or more elongate decking' members fixedly mounted thereto.

11. A pallet comprising: a support member as claimed in Claim 1 in combination with one or more elongate decking members fixedly mounted thereto, the support member having a plurality of laterally extending ribs formed as a continuous formation with the side panel ribs.

15. A pallet as claimed in Claim 11 wherein said elongate d.-ckiiig" member is of a generally \M' shaped section, the lower ends if each of the outer legs of the 'M' ex tending- laterally to form a generally horizontal flange.

16. A method of fabricnt i.ng a support member according to any one A Claims 1 to Claim 11 including the step of roll forming the ribs and flanges in the side panels. .— , v •'» ' v *■*> 7 f' 30 JAN 1992 ? 3 0 8 4 0 21

1". A method of fabricating a supixirt member according to any ono of Claims 1 to Claim 11 including the step of rol ! forming at least. one longitudinal indent ation in the top panel.

18. A method of fabr i eat i ng a support. member accord ir.g to Claim 4 including the step of roll forminq at least one longtitudinal indentation in the base panel.

19. A method of fabricating a support member according to any ono of Claims 6 to Claim 11 including the step of simultaneously roll forming the flanges with the top panel to secure r;aiH top panel to the side panel'.:.

20. A method of fabricating a support member according to any one of CLaims ti to Claim 11 including the step of simultaneously roll forming the f 1 anges with the base p. me I to secure said base panel to the side panel.

21. A method of fabricating a supjiort member according to claim 10 or claim 11 including the step of s imu 1 * an*.-. <i is 1 y roll form in/;' the top panel with the flanges- to draw the longitudinally extending indentation into tight mutually supportive engagement with the run out portion of the ribs in the adjacent side panel.

22. A method of fabricating a support member according' to Claim 10 or Claim 11 including the step of simultaneously roll forming the base panel with the flanges to draw the longitudinally extending' indentation into tight mutually supportive engagement with the run out portion of the ribs in the adjacent side panel.

23. A method of fabricating a pallet according' to Claim 15 including the step of roll forming' the elongate decking member.

24. A method of fabricating a pallet according to Claim 14 including the step of securing' the docking members to the top panel of the support member's. . 'V ?30B4 22

25. A support member substantially as heroin described with reference to and as shown in Figures 5 to 15 of the accompanying drawings.

26. A pal lot substantially as herein described with reference to Figures 5 to 15 of the accompanying drawings.

27. A method of fabricating a support member substantially as herein described with reference to and as shown in Figures 5 to 15 of the accompanying drawings. By Hls/t>tfTr authorised Agents., A. J. PARK. & SON.