WO2006037179A2

WO2006037179A2 - Wire decks and methods of construction

Info

Publication number: WO2006037179A2
Application number: PCT/AU2005/001535
Authority: WO
Inventors: Jason Kenneth Gisler
Original assignee: Gisler Wire Products Pty Ltd
Priority date: 2004-10-06
Filing date: 2005-10-06
Publication date: 2006-04-13
Also published as: WO2006037179A3

Abstract

A deck (10) including: a plurality of spaced apart first wires (11) and a plurality of spaced apart second wires (12) extending across said first wires on one side, at least some of said first and second wires being secured to each other at their respective intersections and at least some of said first wires having a plurality of base portions (19) adapted to cooperate with sai second wires to form a base (15) and a plurality of spaced apart first leg portions (18) depending from adjacent base portions and adapted to rest on a floor to support said base thereabove; and the end portions (13, 14) of at least some of said second wires depend from said base to form second leg portions (16, 17) adapted.to rest on a floor to support said base thereabove; and an edge wire (16, 17) extending across said second wires and secured to at least some of said second wires adjacent their ends.

Description

WIRE DECKS AND METHODS OF CONSTRUCTION FIELD OF THE INVENTION

THIS INVENTION relates to wire decks and methods of constructing decks. The invention has particular application to decks of the type used for supporting goods, particularly foodstuffs, above a floor or shelf and constructed substantially of wire. For example, the invention may have application to decks for supporting goods above a floor or shelf such as in cold rooms. However, the invention is not limited to that field of use.

BACKGROUND OF THE INVENTION

Decks and pallets are sometimes used for supporting meat, fruit, vegetables and other foodstuffs above the floor in cold rooms to allow air circulation around the goods. Some such decks typically have a wire base with elongate horizontal feet formed from folded sheet metal secured thereunder to space the wire base above the cold room floor. The manufacture of that type of deck requires the use of sheet metal handling equipment as well as wire working equipment even though the feet are a relatively minor portion of the deck. Further, moisture often builds up in the channels which results in corrosion and the possibility of the undesirable build up of micro-organisms. Moreover, even for general goods storage in normal warehouse environments, the sheet metal feet can gather dust and debris which can result in early corrosion. All- wire decks have been proposed, but do not always provide a fully planar grid for supporting goods on the upper plane of the deck.

Any reference to prior art in this specification is not to be taken as an admission that such prior art forms part of the common general knowledge to a person of ordinary skill in the art.

The present invention aims to provide a wire deck which ameliorates at least one of the problems and/or shortcomings of the prior art, or at least provides a wire deck having one or more advantages over the prior art. Other aims and advantages of the invention may become apparent from the following description.

SUMMARY OF THE INVENTION

With the foregoing in view, the invention in a first aspect resides broadly in a wire deck including: a plurality of spaced apart first wires and a plurality of spaced apart second wires extending across said first wires on one side, at least some of said first and second wires being secured to each other at their respective intersections to form a deck portion; a plurality of spaced apart third wires secured to at least some of said first wires, at least some of said third wires depending away from said deck portion to support said deck portion thereabove.

Preferably, a plurality of fourth wires are provided in spaced apart relationship along said third wires for securing said third wires to said second wires. In such form, it is preferred that said third wires are secured to one or two of said first wires at or near each end of said third wires. It is also preferred that a plurality of said third wires is secured to each of said fourth wires, said third and fourth wires conforming substantially to a channel configuration in which some of said third wires depend further away from the deck portion than other third wires. In such form, said third and fourth wires form a foot assembly portion, there being a plurality of foot assembly portions being provided in operative association with the deck portion. Advantageously, such arrangement inhibits bending of the wire deck at the legs.

Preferably, said deck portion is generally planar in configuration for supporting thereon bags, boxes, foodstuffs and the like. Preferably, said second wires are substantially perpendicular to said first wires and generally lie in the same plane. Preferably, said end portions depend from said base substantially at right angles such that they carry the down load on their ends. Preferably, said foot assembly portions are substantially V-shaped or U-shaped in section to form said channel configuration. Preferably, the end of each channel configuration depends towards the deck portion to become contiguous therewith to provide for the apex of the V or U to rest on the floor. Preferably, said foot assembly portions are substantially aligned to form spaced apart sets across the underside of the deck portion.

In a second aspect, the invention resides broadly in a method of constructing a wire deck including: placing on a press bed a plurality of third wires in spaced relationship and a plurality of fourth wires extending across said third wires in spaced relationship on one side thereof; pressing at least some of said third and fourth wires to a channel configuration; welding at least some of said third and fourth wires to each other at their respective intersections to form a plurality of spaced apart pressed sets of foot assembly portions in spaced relationship from one another; placing across the foot assembly portions a plurality of first wires in spaced relationship with one another and a plurality of second wires extending across said first wires in spaced relationship on one side thereof remote from the foot assembly portions; welding at least some of said first and second wires to each other at their respective intersections to form a deck portion and welding at least some of said fourth and first wires to each other at their respective intersections to secure said foot assembly portions to said deck portion.

Preferably, the method also includes pressing or folding the end portions of said second wires.

Preferably, the method also includes cutting the second wires to a desired length after pressing and after welding and then welding an edge wire to the end portions of said second wires. hi a third aspect, the present invention resides broadly in a deck including: a plurality of spaced apart first wires and a plurality of spaced apart second wires extending across said first wires on one side, at least some of said first and second wires being secured to each other at their respective intersections; and an edge wire extending across said second wires on the side opposite to said first wires and secured to at least some of said second wires adjacent their ends.

In a fourth aspect the present invention resides broadly in a deck including: a plurality of spaced apart first wires and a plurality of spaced apart second wires extending across said first wires on one side, at least some of said first and second wires being secured to each other at their respective intersections and at least some of said first wires having a plurality of base portions adapted to cooperate to form a base and a plurality of spaced apart first leg portions depending from adjacent base portions and adapted to rest on a floor to support said base thereabove.

In a fifth aspect the present invention resides broadly in a deck including: a plurality of spaced apart first wires and a plurality of spaced apart second wires extending across said first wires on one side, at least some of said first and second wires being secured to each other at their respective intersections and at least some of said first wires having a plurality of base portions adapted to cooperate with said second wires to form a base and a plurality of spaced apart first leg portions depending from adjacent base portions and adapted to rest on a floor to support said base thereabove; and the end portions of at least some of said second wires depend from said base to form second leg portions adapted to rest on a floor to support said base thereabove; and an edge wire extending across said second wires and secured to at least some of said second wires adjacent their ends.In such form of the invention it is preferred that the edge wire be secured on the side of the second wires opposite to that of the first wires. Preferably, said base is generally planar in configuration and is adapted to support thereon bags, boxes, foodstuffs and the like. Preferably, said second wires are substantially perpendicular to said first wires and generally lie in the same plane. Preferably, said end portions depend from said base substantially at right angles such that they carry the down load on their ends. Preferably, said first leg portions are substantially V-shaped or U-shaped with the end of each leg of the V or U being contiguous with the adj acent base portions, such that the apex of the V or U is adapted to rest on the floor.

Preferably, said first leg portions of adjacent wires are substantially aligned to form spaced apart sets across the base. In such form, it is preferred that a plurality of said second wires extend across said first wires within said leg portions in each set and are secured thereto. In such form of the invention, it is preferred that each one of the plurality of second wires in each set of leg portions be secured to the leg portions in order to tie those leg portions together whereby they cooperate to form an elongate support for the base between adjacent base portions. In such form of the invention, it is also preferred that at least a portion of at least some of said second wires in at least some of said sets of leg portions forms a base portion generally lying in the plane of the base. In a preferred form that base portion lies beyond said outermost first wires and an end portion depends therefrom to form one or more of said second leg portions. Advantageously, such arrangement inhibits bending of the deck at the legs.

In a sixth aspect, the present invention resides broadly in a method of constructing a deck including: placing on a press bed a plurality of first wires in spaced relationship and a plurality of second wires extending across said first wires in spaced relationship on one side thereof; pressing at least some of said first and second wires to form a plurality of spaced apart pressed portions in said first wires depending from adjacent portions thereof; and welding at least some of said first and second wires to each other at their respective intersections to form a base having a plurality of spaced apart pressed portions depending therefrom. Preferably, the method also includes pressing or folding the end portions of said second wires.

Preferably, the method also includes cutting the second wires to a desired length after pressing and after welding and then welding an edge wire to the end portions of said second wires.

In a seventh aspect, the present invention resides broadly in a deck including: a plurality of spaced apart first wires and a plurality of spaced apart second wires extending across said first wires on one side, at least some of said first and second wires being secured to each other at their respective intersections to form a deck portion; a plurality of spaced apart third wires secured to at least some of said first wires, at least some of said third wires depending away from said deck portion to support said deck portion thereabove.

Preferably, a plurality of fourth wires are provided in spaced apart relationship along said third wires for securing said third wires to said second wires. In such form, it is preferred that said third wires are secured to one or two of said first wires at or near each end of said third wires. It is also preferred that a plurality of said third wires is secured to each of said fourth wires, said third and fourth wires conforming substantially to a channel configuration in which some of said third wires depend further away from the deck portion than other third wires. In such form, said third and fourth wires form a foot assembly portion, there being a plurality of foot assembly portions being provided in operative association with the deck portion. Advantageously, such arrangement inhibits bending of the deck at the legs.

In an eighth aspect, the present invention resides broadly in a method of constructing a deck including: placing on a press bed a plurality of third wires in spaced relationship and a plurality of fourth wires extending across said third wires in spaced relationship on one side thereof; pressing at least some of said third and fourth wires to a channel configuration; welding at least some of said third and fourth wires to each other at their respective intersections to form a plurality of spaced apart pressed sets of foot assembly portions in spaced relationship from one another; placing across the foot assembly portions a plurality of first wires in spaced relationship with one another and a plurality of second wires extending across said first wires in spaced relationship on one side thereof remote from the foot assembly portions; welding at least some of said first and second wires to each other at their respective intersections to form a deck portion and welding at least some of said fourth and first wires to each other at their respective intersections to secure said foot assembly portions to said deck portion. Preferably, the method also includes pressing or folding the end portions of said second wires.

Preferably, the method also includes cutting the second wires to a desired length after pressing and after welding and then welding an edge wire to the end portions of said second wires. BRIEF DESCRIPTON OF THE INVENTION

In order that the invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate preferred embodiments of the invention and wherein:

Fig. 1 is a perspective view of a wire deck according to the invention; Fig. 2 is an orthographic projection of the wire deck of Fig. 1 ;

Fig. 3 is a perspective view of another wire deck according to the invention;

Fig. 4 is an orthographic projection of the wire deck of Fig. 3;

Fig. 5 is a perspective view of another wire deck according to the invention; and

Fig. 6 is an orthographic projection of the wire deck of Fig. 5. Fig. 7 is a perspective view of an alternative wire deck according to the invention;

Fig. 8 is a detail view of part of the alternative wire deck of Fig. 7; Fig. 9 is an orthographic projection of the alternative wire deck of Fig. 7;

Fig. 10 is a sectional view on A-A of Fig. 9; and

Fig. 11 is a detail view of part of the alternative wire deck on section B of Fig. 9.

DETAILED DESCRIPTION OF THE INVENTION In the Figs., elements depicted which have reference numerals which refer to a typical one of a plurality of such elements are appended with the suffix "typ". The wire deck 10 illustrated in Fig. 1 includes a plurality of parallel spaced apart first wires shown typically at 11 extending in one direction and a plurality of spaced apart generally parallel second wires shown typically at 12 on top of the first wires and extending in a direction generally perpendicular to that of the first wires. The first and second wires are welded together at their respective intersections.

The opposite end portions of the second wires shown typically at 13 and 14 are folded substantially at right angles to the intermediate portion of the second wires to form edge legs which terminate at edge wires 16 and 17 respectively which are welded to the second wires immediately adjacent their respective ends 13a and 14a. Advantageously, the edge wires are welded on the opposite side of the second wires to that of the first wires to provide improved safety characteristics for users.

Each of the first wires include spaced apart leg portions shown typically at 18 and intermediate base portions therebetween shown typically at 19 with the leg portions depending from the adjacent base portions. It will be seen that the base portions lie in a horizontal plane (when in use) and the leg portions lie in an orthogonal vertical plane. Advantageously, the leg portions of the first wires are aligned to form an elongate support shown typically at 21 having a generally V-shaped cross section extending almost fully across the deck in the same direction as the second wires. The leg portions are interconnected by a number of closely placed second wires shown typically at 22 as can be more clearly seen in the detail view at 15, the arrangement being provided to increase the strength of the deck in the vicinity of the legs. It will be seen that the second wires which cross the first wires in the leg portions have a portion 24 towards each end thereof beyond the outermost first wire which lies in the plane of the base portion and are contiguous therewith such that a horizontal platform is created which extends fully across the front and back of each deck adjacent the edge legs 13. The deck 110 illustrated in Fig. 3 is the same as that of Fig. 1 and accordingly corresponding components have been referenced by the same numbers except that they are prefaced by a "1 ". The main difference from the deck of Fig. 1 is that deck 110 has three second wires 122 extending through the leg portions rather than four, with one of those wires being located in the apex of the V-shaped leg portions 118.

The deck 210 illustrated in Fig. 5 is the same as that of Fig. 1 in many respects and accordingly corresponding components have been referenced by the same numbers except that they are prefaced by a "2". The main difference is that the supports are formed from third and fourth wires 231 and 232 having leg portions formed therein 233 rather than from leg portions formed in the first and second wires as in the decks of Figs. 1 and 2. Each of the leg portions has much the same shape as the leg portion in the earlier described decks and each of those leg portions is welded to the spaced apart second wires 212 and 234 on the opposite sides of the leg portions between respective adjacent first wires 211 and the aligned legs are crossed by a plurality of fourth wires shown typically at 236 which are welded thereto. Advantageously, the deck 210 has edge wires 216 and 217 in the same form as that of the other decks.

The decks shown in Figs. 1 and 2 are manufactured by laying the set of first wires on a press bed in the desired spaced apart positions and then laying the second wires on top in their desired spaced apart positions. The press head is then lowered to press the leg portions in the first wires and the bends in the second wires as desired as well as the folds at the ends of the second wires. Once the wires have been pressed into the desired form they are welded together at the intersections while on the press bed. After the first and second wires are welded together, the edge wires 18 and 19 are positioned as shown in Fig. 1 and welded to the second wires in the desired respective positions. The second wires are then cut off immediately adjacent the edge wires. Advantageously, the method accommodates the drawing of the first and second wires to different lengths as required to suit the leg portions in the first wires and the bends in the second wires which cross the leg portions as required. hi another method, the first and second wires can be cut to a predetermined length and laid on the press bed in the desired positions and welded prior to pressing. Subsequently, the edge wires can be welded to the second wires immediately adjacent the ends which should be all aligned.

The deck shown in Fig. 5 can be formed in much the same manner as those of Figs. 1 and 2. However, for that embodiment, it is necessary to lay the third and fourth wires on the press bed first and press them into the desired form prior to laying the first and second wires in the desired position.

The alternative wire deck 310 illustrated in Fig. 7 includes a plurality of parallel spaced apart first wires 311 extending in one direction and a plurality of spaced apart generally parallel second wires 312 on top of the first wires and extending in a direction generally perpendicular to the first wires. The first and second wires are welded together at their respective intersections to form a deck portion.

The opposite end portions of the second wires 313 and 314 are folded substantially at right angles to the intermediate portion of the second wires to form edge legs which terminate at edge wires 316 and 317 respectively which are welded to the second wires immediately adjacent their respective ends 313a and 314a. Advantageously, the edge wires are welded on the opposite side of the second wires to that of the first wires to provide improved safety characteristics for users.

At four regularly spaced intervals along the first wires are provided substantially identically shaped third wires 318. Each of the third wires includes two intermediate portions 321 which depend away from the first wires from respective end portions 322 to meet a central portion 320 which is spaced from the first and second wires and substantially parallel to the second wires. The third wires are provided in sets of four and are welded immediately adjacent their respective ends to the edge wires. The intermediate portions slope substantially linearly away from the plane of the first and second wires, the outer two of the fourth wires having their central portions closer to the second wires and the inner two having their central portions spaced from the second wires about the same distance that the edge wires are spaced from the plane of the first and second wires. Such an arrangement permits the third wires to function as legs ("intermediate legs") intermediate the edge legs described above.

A plurality fourth wires is provided between the second and third wires in substantial alignment with the first wires. Except for the second ones of the first wires from the edge, the fourth wires are spaced evenly from each of the adjacent first wires in pairs, and extend in length only between the outer ones of the forth wires in each set. For each set of third and fourth wires, a second wire 312a is provided such that the spacing of the second wires is not upset by the provision of the intermediate legs. Each such second wire 312a is aligned substantially centrally along the elongate axis of the relevant intermediate leg. For each intermediate leg, an extra pair of third wires 318a is provided below the fourth wires and adjacent and below the second wires each side of the second wire central of the intermediate leg. The third and fourth wires are welded to one another at their respective intersections, the intermediate legs being welded to the deck portion where the ends of the fourth wires intersect with the relevant second wires, as well as the third wires being welded to the edge wires in similar fashion to the second wires being welded thereto.

It will be seen that the deck portion lies in a horizontal plane (when in use)and the third wires lie in an orthogonal vertical plane. Advantageously, the intermediate legs are aligned to form an elongate support having a generally V-shaped cross section extending almost fully across the wire deck in the same direction as the second wires. The third and fourth wires are arranged to increase the strength of the wire deck in the vicinity of the legs.

The alternative wire decks shown in Figs. 7 and 8 are manufactured by laying the set of third wires on a press bed in the desired spaced apart positions and then laying the fourth wires on top in their desired spaced apart positions. The press head is then lowered to press the bends in the third and fourth wires as desired to form the intermediate legs. The set of first wires are then laid on the press bed in the desired spaced apart positions and the second wires laid on top in their desired spaced apart positions. The press head (or another press head) is lowered to form the the folds at the ends of the second and third wires. Once the wires have been pressed into the desired form they are welded together at the intersections while on the press bed. After the first and second wires are welded together, the edge wires 318 and 319 are positioned as shown in Fig. 8 and welded to the second wires in the desired respective positions. The second and third wires are then cut off immediately adjacent the edge wires. Advantageously, the method accommodates the drawing of the third wires to different lengths as required to suit the intermediate legs.

In another method, the second and third wires can be cut to a predetermined length and laid on the press bed in the desired positions. Subsequently, the edge wires can be welded to the second wires immediately adjacent the ends which should be all aligned.

The foregoing description has been given by way of illustrative example of the invention and many modifications and variations which will be apparent to persons skilled in the art may be made without departing from the spirit and scope of the invention as defined in the appended claims.

Claims

1. A deck including: a plurality of spaced apart first wires and a plurality of spaced apart second wires extending across said first wires on one side, at least some of said first and second wires being secured to each other at their respective intersections; and an edge wire extending across said second wires on the side opposite to said first wires and secured to at least some of said second wires adjacent their ends.

2. A deck including: a plurality of spaced apart first wires and a plurality of spaced apart second wires extending across said first wires on one side, at least some of said first and second wires being secured to each other at their respective intersections and at least some of said first wires having a plurality of base portions adapted to cooperate to form a base and a plurality of spaced apart first leg portions depending from adjacent base portions and adapted to rest on a floor to support said base thereabove.

3. A deck including: a plurality of spaced apart first wires and a plurality of spaced apart second wires extending across said first wires on one side, at least some of said first and second wires being secured to each other at their respective intersections and at least some of said first wires having a plurality of base portions adapted to cooperate with said second wires to form a base and a plurality of spaced apart first leg portions depending from adjacent base portions and adapted to rest on a floor to support said base thereabove; and the end portions of at least some of said second wires depend from said base to form second leg portions adapted to rest on a floor to support said base thereabove; and an edge wire extending across said second wires and secured to at least some of said second wires adjacent their ends.

4. A deck according to any one of the preceding claims, wherein said base is generally planar in configuration and is adapted to support thereon bags, boxes, foodstuffs and the like.

5. A deck according to any one of the preceding claims, wherein said second wires are substantially perpendicular to said first wires and generally lie in the same plane.

6. A deck according to any one of the preceding claims, wherein said end portions depend from said base substantially at right angles.

7. A deck according to any one of the preceding claims, wherein said first leg portions are substantially V-shaped or U-shaped with the end of each leg of the V or U being contiguous with the adj acent base portions, such that the apex of the V or U is adapted to rest on the floor and said first leg portions of adjacent wires are substantially aligned to form sets of spaced apart leg portions across the base.

8. A deck according to any one of the preceding claims, wherein the edge wire is secured to the second wires on the side opposite to that of the first wires.

9. A deck according to any one of the preceding claims, wherein a plurality of second wires extend across said first wires within said leg portions in each set and are secured thereto.

10. A deck according to Claim 9, wherein each one of the plurality of second wires hi each set of leg portions is secured to the leg portions in order to tie those leg portions together whereby they cooperate to form an elongate support for the base between adjacent base portions.

11. A deck according to Claim 10, wherein at least a portion of at least some of said second wires in at least some of said sets of leg portions forms a base portion generally lying in the plane of the base.

12. A deck according to Claim 11 , wherein that base portion lies beyond said outermost first wires and an end portion depends therefrom to form one or more of said second leg portions.

13. A method of constructing a deck including: placing on a press bed a plurality of first wires in spaced relationship and a plurality of second wires extending across said first wires in spaced relationship on one side thereof; pressing at least some of said first and second wires to form a plurality of spaced apart pressed portions in said first wires depending from adjacent portions thereof; and welding at least some of said first and second wires to each other at their respective intersections to form a base having a plurality of spaced apart pressed portions depending therefrom.

14. A method according to Claim 13, including pressing or folding the end portions of said second wires.

15. A deck according to Claim 13 or Claim 14, including cutting the second wires to a desired length after pressing and after welding and then welding an edge wire to the end portions of said second wires.

16. A deck as hereinbefore described with reference to any of the accompanying drawings.

17. A method as hereinbefore described with reference to any of the accompanying drawings.

18. A deck including: a plurality of spaced apart first wires and a plurality of spaced apart second wires extending across said first wires on one side, at least some of said first and second wires being secured to each other at their respective intersections to form a deck portion; a plurality of spaced apart third wires secured to at least some of said first wires, at least some of said third wires depending away from said deck portion to support said deck portion thereabove.

19. A deck according to Claim 18, wherein a plurality of fourth wires are provided in spaced apart relationship along said third wires for securing said third wires to said second wires.

20. A deck according to Claim 19, wherein said third wires are secured to one or two of said first wires at or near each end of said third wires.

21. A deck according to any one of Claims 18 to 20, wherein a plurality of said third wires is secured to each of said fourth wires, said third and fourth wires conforming substantially to a channel configuration in which some of said third wires depend further away from the deck portion than other third wires.

22. A deck according to Claim 21 , wherein said third and fourth wires form a foot assembly portion, there being a plurality of foot assembly portions being provided in operative association with the deck portion.

23. A deck according to any one of Claims 18 to 22, wherein said second wires are substantially perpendicular to said first wires and generally lie in the same plane.

24. A deck according to any one of Claims 18 to 23, wherein said end portions depend from said base substantially at right angles such that they carry the down load on their ends.

25. A deck according to any one of Claims 22 to 24, wherein said foot assembly portions are substantially V-shaped or U-shaped in section to form said channel configuration, the end of each channel configuration depending towards the deck portion to become contiguous therewith to provide for the apex of the V or U to rest on the floor.

26. A method of forming a deck including: placing on a press bed a plurality of third wires in spaced relationship and a plurality of fourth wires extending across said third wires in spaced relationship on one side thereof; pressing at least some of said third and fourth wires to a channel configuration; welding at least some of said third and fourth wires to each other at their respective intersections to form a plurality of spaced apart pressed sets of foot assembly portions in spaced relationship from one another; placing across the foot assembly portions a plurality of first wires in spaced relationship with one another and a plurality of second wires extending across said first wires in spaced relationship on one side thereof remote from the foot assembly portions; welding at least some of said first and second wires to each other at their respective intersections to form a deck portion and welding at least some of said fourth and first wires to each other at their respective intersections to secure said foot assembly portions to said deck portion.

Dated this 5^th day of October, 2005

Gisler Wire Products Pty Ltd

By their Patent Attorneys

AHEARN FOX