Freewheel flow track systems

Abstract

Freewheel flow track systems are adapted for transporting pallets and/or cartons in heavy-duty pallet and carton flow applications. A flow track system may include multiple track sub-assemblies, each track sub-assembly including multiple wheel assemblies. Each wheel assembly comprises a wheel rotatably mounted on an axle. A lubricant coating may be fixed to and bonded with the axle. The wheel may be constructed from a polycarbonate-based resin that is impregnated with a lubricant for providing lifetime lubrication to the wheels. The wheel includes a hub, a rim concentric with the hub, a web connecting the hub to the rim, and ribs connecting the hub to the rim through the web.

1 . A conveyor system comprising:
 a track assembly comprising a first frame member and a second frame member, the frame members spaced apart from each other; and   a wheel assembly comprising an axle and a plurality of wheels, the axle extending between the frame members, each wheel rotatably mounted to the axle, each wheel comprising:
 a central hub, 
 a rim concentric with the hub, 
 a web extending between the hub and the rim, 
 a first set of ribs positioned on a first side of the wheel, and 
 a second set of ribs positioned on a second side of the wheel, the second set of ribs offset from the first set of ribs by an offset angle. 
   
   
   
       2 . The conveyor system of  claim 1 , wherein the axle is at least partially coated in a lubricant coating. 
   
   
       3 . The conveyor system of  claim 2 , wherein the lubricant coating is bonded to the axle. 
   
   
       4 . The conveyor system of  claim 2 , wherein the lubricant coating comprises at least one of the following materials: a fluorocarbon-based lubricant or a Teflon-based lubricant. 
   
   
       5 . The conveyor system of  claim 1 , wherein at least one of the wheels comprises a polycarbonate-based resin. 
   
   
       6 . The conveyor system of  claim 5 , wherein the polycarbonate-based resin is impregnated with a lubricant. 
   
   
       7 . The conveyor system of  claim 6 , wherein the lubricant comprises at least one of the following materials: silicone and molybdenum. 
   
   
       8 . The conveyor system of  claim 1 , wherein at least one of the wheels comprises PC/PET  325 . 
   
   
       9 . The conveyor system of  claim 1 , wherein each rib is spaced apart by an inter-rib angle such that cavities are defined between consecutive ribs. 
   
   
       10 . The conveyor system of  claim 1 , wherein each rib comprises:
 a first leg extending from the hub to an intersection of the hub and the web;   a second leg extending across the web; and   a third leg extending from an intersection of the web and the rim to the rim.   
   
   
       11 . The conveyor system of  claim 1 , wherein the axle comprises a first end portion associated with the first frame member and a second end portion associated with the second frame member, the first end portion comprising a first dimple that engages a first axle mounting hole in the first frame member. 
   
   
       12 . The conveyor system of  claim 11 , wherein the second end portion comprises a second dimple that engages a second axle mounting hole in the second frame member. 
   
   
       13 . A conveyor system comprising:
 a track assembly comprising a first frame member and a second frame member, the frame members spaced apart from each other;   a wheel assembly comprising an axle and a plurality of wheels, the axle extending between the frame members, each wheel rotatably mounted to the axle, each wheel comprising:
 a central hub, 
 a rim concentric with the hub, 
 a web extending between the hub and the rim, and 
 a plurality of ribs connecting the hub to the rim through the web, each rib comprising a first leg extending from the hub to a hub-web junction, a second leg extending from the hub-web junction to a rim-web junction, and a third leg extending from the rim-web junction to the rim. 
   
   
   
       14 . A conveyor system comprising:
 a track assembly comprising a first frame member and a second frame member, the frame members spaced apart from each other;   a first wheel assembly comprising:
 an first axle extending between the frame members, 
 a set of first wheels, the first wheels rotatably mounted to the first axle, the first wheels spaced apart from each other along the first axle; 
   a second wheel assembly comprising:
 a second axle extending between the frame members, and 
 a set of second wheels, each second wheel rotatably mounted to the second axle, the second wheels spaced apart from each other along the second axle, the second wheels staggered with reference to the first wheels. 
   
   
   
       15 . The conveyor system of  claim 14 , wherein the first axle comprises a first end portion associated with the first frame member and a second end portion associated with the second frame member, the first end portion comprising a first dimple that engages a first axle mounting hole in the first frame member. 
   
   
       16 . The conveyor system of  claim 15 , wherein the second end portion comprises a second dimple that engages a second axle mounting hole in the second frame member. 
   
   
       17 . The conveyor system of  claim 14 , wherein the first axle is at least partially coated in a lubricant coating. 
   
   
       18 . The conveyor system of  claim 17 , wherein the lubricant coating is bonded to the first axle. 
   
   
       19 . The conveyor system of  claim 14 , wherein at least one of the wheels comprises a polycarbonate-based resin. 
   
   
       20 . The conveyor system of  claim 19 , wherein the polycarbonate-based resin is impregnated with a lubricant.