Method for product handling using a configurable display container

Abstract

A method for product handling includes filling a reusable container at a facility with a pre-selected amount of product. The container is sized and configured for display at a retail location and includes a set of joined walls where some of the walls are configured to move relative to a bottom wall of the container. The set of joined walls move relative to the bottom wall to convert the container between an enclosed configuration enclosing an internal volume and a display configuration providing a side access opening and a top access opening to the internal volume such that the side and top access openings allow product to be removed from the container. The container is converted to the enclosed configuration by closing at least one of the top and side access openings to the container through which the container was filled with the pre-selected amount of product by moving at least one wall of the set of joined walls of the container relative to the bottom wall of the container. The container is transported in its enclosed configuration to the retail location.

Description

TECHNICAL FIELD

The present application relates to a method for product handling using a display configurable container.

BACKGROUND

Palletized loads are commonly used to transport product. Typically, the product is placed in a container that is, in turn, stacked on a pallet resting on the ground. The pallet is used to move the container from one location to another using a forklift.

To provide greater flexibility in palletizing, slipsheet palletizing has been proposed where a thin sheet of material is interposed between adjacent units of product that are stacked one on top of the other. To remove the top unit, a modified forklift or lift truck having a gripping device is used. The gripping device can grasp an edge of the slipsheet and pull the slipsheet including the unit disposed thereon onto the forklift or lift truck.

While use of a forklift and palletized loads may be suitable for certain products at some stages during the distribution process, they are not particularly well-suited to accomplish many downstream processes, for example, where greater flexibility may be important such as in re-stocking store displays from a storage location. Often times, once the pallet of containers reaches a retail location, the product is removed from the container and then placed on a shelf for display. Or, in some instances, the product is removed and transferred to a second, display container that allows customers to view the product placed therein.

SUMMARY

In an aspect, a method for product handling includes filling a reusable container at a facility with a pre-selected amount of product. The container is sized and configured for display at a retail location and includes a set of joined walls where some of the walls are configured to move relative to a bottom wall of the container. The set of joined walls move relative to the bottom wall to convert the container between an enclosed configuration enclosing an internal volume and a display configuration providing a side access opening and a top access opening to the internal volume such that the side and top access openings allow product to be removed from the container. The container is converted to the enclosed configuration by closing at least one of the top and side access openings to the container through which the container was filled with the pre-selected amount of product by moving at least one wall of the set of joined walls of the container relative to the bottom wall of the container. The container is transported in its enclosed configuration to the retail location.

In another aspect, a method for displaying a product for retail sale is provided. The method includes converting a reusable container from a collapsed configuration where walls of a set of joined walls are folded over a bottom wall of the container to form a layered stack of walls to a display configuration by moving walls of the set of joined walls relative to the bottom wall. The container is sized for placement on a shelf of a display with the container in the display configuration. The container is filled at a facility with a pre-selected amount of product for retail sale with the container in the display configuration. The container is converted to an enclosed configuration where the set of joined walls enclose the pre-selected amount of product.

In another aspect, a method of handling an item includes filling a reusable container at a facility with a pre-selected amount of items with the container in a display configuration. The container includes a set of joined walls where some of the walls are configured to move relative to a bottom wall of the container to convert between an enclosed configuration enclosing an internal volume and the display configuration providing a side access opening and a top access opening to the internal volume such that the side and top access openings allow the items to be removed from the container. The container is converted from the display configuration to the enclosed configuration by closing the top and side access openings by moving at least two joined walls of the set of joined walls of the container relative to the bottom wall of the container.

The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a method and apparatus for handling containers;

FIG. 2 is a front view of an embodiment of a container handling apparatus for a container;

FIG. 3 is a side view of the handling apparatus of FIG. 2;

FIG. 4 is a side view of an embodiment of a container manipulation device;

FIG. 5 is a top view of the container manipulation device of FIG. 4;

FIG. 6 is a top view of an embodiment of an interlocking member;

FIG. 7 is a side view of the interlocking member of FIG. 6;

FIG. 8 is a perspective view of an embodiment of a container suitable for use with the transport device of FIG. 2 in an enclosed configuration;

FIG. 9 is a detail view of an embodiment of a device engagement structure;

FIG. 10 is a side, section view of the device engagement structure of FIG. 9 along line 10-10;

FIG. 11 is a side, section view of the device engagement structure along line 11-11 of FIG. 9 engaged with the interlocking member of FIG. 6;

FIG. 12 is a detail view of another embodiment of a device engagement structure;

FIG. 13 is a partial, top view of another embodiment of an interlocking member;

FIG. 14 is a partial, top view of another embodiment of an interlocking member;

FIG. 15 is a prospective view of the container of FIG. 8 in a display configuration;

FIG. 16 is a side, detail view of an embodiment of a joint at area J of FIG. 15;

FIG. 17 is a side, detail view of another embodiment of a joint at area J of FIG. 15;

FIG. 18 is a perspective view of the container of FIG. 15 without any articles therein;

FIG. 19 is a side, section view of the container of FIG. 18 with an article being removed;

FIG. 20 is a side, section view of the container of FIG. 18 in a collapsed configuration;

FIG. 21 is a front, section view of the container of FIG. 18 in the collapsed configuration;

FIGS. 22A-22I illustrate a method of transforming the container of FIG. 18 between the enclosed, display and collapsed configurations;

FIG. 23 is a side view of an alternative embodiment of a container;

FIG. 24 is a side view of the container of FIG. 23 with its top and front walls moved toward the display configuration;

FIG. 25 is a perspective view of an embodiment of an aisle display;

FIG. 26 is a front view of another embodiment of a display;

FIG. 27 is a side view of the display of FIG. 26;

FIG. 28 is a side view of an alternative embodiment of the display of FIG. 26;

FIGS. 29 and 30 are a method of restocking a display using the transport device of FIG. 2 and the container of FIG. 8;

FIG. 31 is a side view of the container of FIG. 8 being lifted by the handling apparatus of FIG. 2;

FIG. 32 is a diagrammatic view of a method and apparatus for filling the container of FIG. 8;

FIG. 33 is a an embodiment of a unitized arrangement of a product; and

FIG. 34 is a front view of an embodiment of a pallet of containers.

DETAILED DESCRIPTION

Referring to FIG. 1, a user 1 is shown retrieving a filled container 50″ from an on-site storage location 2 including a storage system 11 using a container handling apparatus 10. Container 50″ is being retrieved from the storage system 11 to replace an empty container 50′ located on a shelf 3 of an end-aisle store display 7 disposed between aisles 4 and 5 of a retail location 6, in this example, a supermarket. The store display 7 includes multiple, display configurable containers 50 placed upon shelves 3 of the display 7. Each container 50 has a prepackaged amount of product 9 disposed therein and is capable of displaying the product 9 for customer viewing and purchase. The handling apparatus 10 can, itself, locate the container 50″ both vertically by lifting the container 50″ and horizontally by pushing the container 50″ to facilitate positioning of the container 50″ on the display 7. The handling device 10 can also remove a container 50 from the shelf 3 or storage system 11 by pulling the container 50 therefrom using interlocking structure capable of engaging the container 50.

Storage system 11 may not be at on-site storage location 2. Instead, storage system 11 may be located at an off-site production facility, warehouse, regional distribution center, consolidation center, etc. By “off-site,” we refer to a facility that is geographically removed from the retail location 6. Containers 50 can be both filled with a predetermined amount of product and stored, at least temporarily, at the off-site facility. An automated container handling system (not shown) may be used to place the containers 50 in, remove the containers 50 from and move the containers 50 between locations in the storage system 11. Containers 50 can be removed from the storage system 11 at the off-site facility and then transported (e.g., by truck, ship or airplane) to the on-site storage location 2. At the on-site location 2, the container 50 may be stored in an enclosed configuration where an internal volume is enclosed by the container 50 or placed on the shelf 3 of the store display 7 in a display configuration where access openings are provided to the internal volume of the container 50 to allow a customer to remove product 9 therefrom. An example of a suitable storage system 11 is described in detail in pending U.S. patent application Ser. No. ______, entitled “Storage System and Method,” filed Mar. 9, 2005 (attorney docket no. 058420-016), the content of which is hereby incorporated by reference as if fully set forth herein.

The user 1 can transport a container 50 from the storage location 2 to the display 7 using handling apparatus 10. Referring to FIG. 2, the handling apparatus 10 includes a mast 12 and a base 14 connected to the mast 12. The base 14 can include, for example, a battery (not shown) and/or other components for automating aspects of the handling apparatus. The mast 12 may include multiple stages (not shown) where a first stage moves relative to a second stage. The stages may or may not be nesting. A handle 16 is also connected to the mast 12 and can facilitate user control of the handling apparatus 10. A container manipulation device 18 is provided that is vertically and horizontally positionable relative to the mast 12.

In some embodiments, wheels 40 may be driven by a motor (e.g., an electric motor connected to a power source, such as a battery). In some instances, the handling apparatus 10 is moved manually under the power of a user with the user walking behind the handling apparatus 10. In some embodiments, the handling apparatus 10 includes a controller (not shown) that allows the user to control movement of the container manipulation device 18 and/or wheel rotation in cases where the handling apparatus 10 is motorized.

Referring also to FIG. 3, the container manipulation device 18 can lift, lower, push and pull a container during a load/unload operation. In particular, container manipulation device 18 includes a support member 20 that forms a planar support surface 22 upon which a container can rest and a container interlocking member 24 that can engage a container to pull the container along the support surface 22. The support member 20 is moveable in a vertical direction 31 relative to the mast 12 for vertically positioning a container at a desired elevation. The interlocking member 24 is carried by the support member 20 and is moveable in a horizontal direction 32 relative to both the mast 12 and the support member 22 for horizontally positioning a container at a desired location.

The support member 20 can be formed of any suitable material including metal, plastic, low friction materials, such as nylon, polytetrafluoroethylene (PTFE), etc. A low friction coating such as Teflon® or Formica® may be applied to the support member 20 to form a low friction support surface 22. In some embodiments, the support member 20 may include a dynamic support (e.g., an array of rollers, balls, etc.) upon which an article can rest. By dynamic support, we refer to a support capable of interacting with a load supported thereon to actively facilitate movement of the load relative to a reference, such as mast 12. Use of low friction or dynamic supports can be particularly advantageous where relatively heavy loads are moved (e.g., 100 pounds or more). Examples of various dynamic supports can be found in pending U.S. patent application Ser. No. ______, already incorporated by reference above.

A container guard 30 includes a central mesh portion 33, e.g., formed of metal, netting or plastic wire, however, other configurations are possible, such as a solid portion rather than a mesh portion. The solid portion can be formed of a transparent material, e.g., to allow a user to see through the container guard 30 while moving a container. The container guard 30 can inhibit spilling of articles from the container when the container is being transported and can serve as a pushing element for applying a pushing force to the container.

Referring also to FIG. 4, a mover 34 carries each of the engaging member 26 and the container guard 30. As can be seen most clearly by FIG. 5, the mover 34 rides along the support surface 22 in a track 36 carried by the support member 22. The track 36 extends substantially linearly between a front edge 37 of the support member 20 relatively far from the mast 12 and an opposite rear edge 39 of the support member 20 relatively near to the mast 12. While a linear track 36 is illustrated, the track may not be linear. Additionally, other arrangements may be utilized to move the interlocking member 24 and the container guard 30. For example, the interlocking member 24 and container guard may be capable of independent movement. The mover 34 may ride along a guide rail. In some embodiments, the interlocking member 24 and/or container guard 30 may not contact or ride along the support member 20 as one or both move horizontally. Instead, the interlocking member 24 and/or container guard 30 may overhang the support surface 22 and be carried, for example, by a mechanical linkage configured to extend and retract the interlocking member 24 and/or container guard 30.

Referring to FIG. 6, the interlocking member 24 includes engaging member 26 disposed at a free end of the interlocking member 24 and a connecting member 38 connecting the interlocking member 24 and the mover 34. Referring also to FIG. 7, the engaging member 26 and connecting member 38 form a substantially T-shaped projection extending integrally from the mover 34 having opposite free ends 83, 85 located at either side of the connecting member 38. While FIGS. 6 and 7 illustrate a substantially T-shaped interlocking member 24, other configurations are possible such as a substantially L-shaped interlocking member, a substantially U-shaped interlocking member, etc.

Any suitable method or device can be used to move the support member 20 and the interlocking member 24. In one embodiment, one or more electric motors (not shown) are used to move the support member 20 vertically and the mover 34 horizontally. The motor may be connected to a power source, such as a battery (not shown) and may or may not be located in the base 14. A transmission belt, chain or other mechanical connection (not shown) can be used to connect the motor to the support member 20. Air and/or hydraulic cylinders (not shown) may be used to move the support member 20 vertically and/or the interlocking member 24 horizontally. The cylinders may be rodless. The air or hydraulic cylinder may be connected directly to the container manipulation device 18, or it may be mechanically connected using a linkage. A container handling device is also described in pending U.S. patent application Ser. No. ______, entitled “Container Handling Apparatus and Container,” filed the same day as the instant application (attorney docket no. 058420-019), the details of which are hereby incorporated by reference as if fully set forth herein.

Referring now to FIG. 8, an example of a container 50 suitable for use with handling apparatus 10 includes a top wall 52, a bottom wall 54 and side walls 56 extending between the top 52 and bottom 54 walls. The side walls 56 include a front wall 58, a rear wall 60 and two end walls 62 and 64 extending between the front and rear walls 58, 60. The top wall 52, bottom wall 54, front wall 58, rear wall 60, and end walls 62 and 64 are interconnected by joints A-E. A lock 59 allows the front wall 58 to lock in its closed position to the bottom wall 54.

Front wall 58 is formed of a transparent material to allow for viewing of contents within the container 50 while the container 50 is in the enclosed configuration. In other embodiments, front wall 58 may not be transparent or front wall 58 may be semi-transparent. The other sidewalls 56, top wall 52 and/or bottom wall 54 may also be formed of a thermoplastic, such as a transparent, non-transparent, or semi-semi-transparent thermoplastic. A suitable transparent material includes clear thermoplastics such as a clear polycarbonate. In some embodiments, the side walls 56, top wall 52 and bottom wall 54 may be formed of any other suitable materials such as food grade materials, plastics, metal, wood, etc. Lightweight materials may also be used. In some instances, container 50 has an unfilled weight of about 20 pounds or less, such as about 16 pounds.

Each end wall 62 and 64 includes a user graspable structure 72. As shown, the user graspable structures 72 are formed by an opening 73 extending through the respective end wall 62, 64 from one side 74 of the end wall 64 to the other side 76 of the end wall 64. In other embodiments, the user graspable structure 72 may not extend entirely through the end walls 62 and 64 or, for example, the graspable structure 62 may be a handle (not shown) mounted to a side 74 of the end wall 64.

Formed as part of bottom wall 54 is engagement structure 68 that is capable of engagement with interlocking member 24. Engagement between the device engagement structure 68 and the interlocking member 24 enables the handling apparatus 10 to pull the container 50 onto the support structure 20 and to lift the container of an underlying surface, such as a shelf.

Referring to FIG. 9, the device engagement structure 68 of the container 50 is a recess 80 that is sized and configured to receive the engaging member 26. In the illustrated embodiment, the recess 80 extends inwardly from a surface of the bottom wall 54, however, other configurations are possible, such as forming the recess 80 to extend inwardly from an outer surface of one or more of the side walls 56. The recess 80 is contoured to form a notch portion 82 that is disposed between two side portions 81 and 83.

Referring to FIG. 10, the side portions 81 include an inwardly facing, U-shaped receiving portion 84 disposed on opposite sides of the notch portion 82. U-shaped receiving portions 84 include a lower surface 95, a side surface 89 and a top surface 91. Notch portion 82 provides a clearance C between the lower surface 95 and upper notch surface 93.

Referring now to FIG. 11, notch portion 82 allows the interlocking member 24 to move vertically with the engaging member 26 disposed within the recess 80. As shown by the dotted lines, interlocking member 26 is located beneath the U-shaped receiving portion 84 when initially disposed within recess 80. Once the engaging member 26 is located behind the U-shaped receiving portion 84 by extending the interlocking member 24, the interlocking member 24 can be moved vertically by raising the support member 20 such that the notch portion 82 receives the connecting member 38 of the interlocking member 24. This vertical motion of the interlocking member 26 can place the engaging member 26 at an entrance 87 to the U-shaped receiving portion 84. Retracting interlocking member 24 locates engaging member 26 within the U-shaped receiving portion 84. Additional retraction of the interlocking member 24 engages the engaging member 26 with the side surface 89 of the U-shaped receiving portion 84 and pulls container 50 in a direction toward the handling apparatus 10. Similarly, additional vertical motion of the interlocking member 24 engages the engaging portion 26 with top surface 91 of the U-shaped receiving portion 84 and lifts at least a portion of the container 50.

Referring still to FIG. 11, once located within the U-shaped receiving portion 84, the engaging member 24 forms a pivot axis P about which the container 50 can pivot in the direction of arrow 86. This can be desirable when lifting an edge of the container 50 off of a support surface on which it rests prior to or while pulling the container 50 toward the handling apparatus 10. By providing P, relatively little torque is applied to the engaging structure 24 and the device engagement structure 68 of the container 50. This can be particularly advantageous when loading or unloading a relatively heavy load.

In an alternative embodiment as shown by FIG. 12, the container engagement structure 90 is contoured to include a first notch portion 92 and a second notch portion 94 disposed on opposite sides of a U-shaped portion 84. Container engagement structure can be sized and configured to receive U-shaped interlocking member 96 such as that shown by FIG. 13 or an L-shaped interlocking member 98 such as that shown by FIG. 14. In other embodiments, the container engagement structure has only a single notch portion, more than two notch portions and/or more than two U-shaped receiving portions. In some instances, the receiving portion 84 may not be U-shaped. In these instances, the receiving portion may only include a side surface 89 and a top surface 91, but not a lower surface 95 (FIG. 10).

Referring to FIG. 15, the set of walls are interconnected by joints A-E to allow for movement of the top wall 52 and the side walls 56 relative to the bottom wall 54. Joint A connects front wall 58 and top wall 52 along opposing lateral edges of the front and top walls 58, 52, joint B connects top wall 52 and rear wall 60 along opposing lateral edges of the top and rear walls 52, 60 and joint C connects rear wall 60 and bottom wall 54 along opposing lateral edges of the rear and bottom walls 60, 54. As can be seen, front wall 58, top wall 52, rear wall 60 and bottom wall 54 form a bi-folding member 75 having two joints A and B that can be moved relative to the bottom wall 54 to provide access to the internal volume. Joint D connects end wall 62 and bottom wall 54 along opposing lateral edges of the end and bottom walls 62, 54, while joint E connects end wall 64 and bottom wall 54 along opposing lateral edges of the end and bottom wall 64, 54. Each of the joints A-E provides an axis of rotation between its respective joined walls that lies substantially parallel to the bottom wall 54. In alternative embodiments, pairs of the side walls 56 of the container 50 may be connected by a joint (not shown) extending along opposing vertical edges 67 of the respective pair of walls forming a respective axis of rotation that is not parallel to the bottom wall 54. In some embodiments, the axis of rotation may be about perpendicular to the bottom wall 54.

Joints A-E can be of any suitable type. However, the type of joint should be selected based, at least in part, on its rotational requirements. For example, joint A should be capable of rotating front wall 58 from its enclosed location to its location resting adjacent top wall 52 and joint B should be capable of rotating top wall 52 from its enclosed location to its location resting adjacent rear wall 60 to form bi-folding member 75. In some embodiments, joints A and B are capable of rotating about 360 degrees or less, such as about 270 degrees. Alternatively, joints C, D and E may be capable of rotating about 90 degrees or less depending on the rotational requirements. In some instances, any of the joints A-E may be capable of rotating more than 90 degrees.

Referring to FIG. 16, joint B is a living hinge 100 formed integrally of material forming top wall 52 and front wall 58 (in some embodiments, during a molding process). Joint B can be formed of an elastic material having a weakened region 111 that facilitates folding of the top and front walls at joint B. Referring to FIG. 17, joint B is formed by a mechanical hinge 112 that interconnects the front wall 58 and the top wall 52. The mechanical hinge 112 can be mechanically connected to the front wall 58 and the top wall 52, for example, after the walls 52 and 58 are formed (e.g., by mechanical fasteners). In some embodiments, the joints are formed of a food grade, corrosion resistant material.

Referring now to FIG. 18, container 50 is shown in the display configuration without contents. Top access opening 66 provides access to container volume 105 through a top of the container 50 while side access opening 69 provides access to container volume 105 through a side of the container 50. Side access opening 69 extends uninterrupted from the bottom wall 54 to the top access opening 66 without any obstruction, such as a lip, extending into or otherwise inhibiting access to the container volume 105 through the side access opening 69. This can allow for linear, horizontal removal of articles from the container 50, for example, by sliding an article along a bottom surface 116 of the container 50 without lifting the article off of the bottom surface 116.

Top access opening 66 extends uninterrupted from rear wall 60 to side access opening 69 without any obstruction extending into or otherwise inhibiting access to the container volume 105 through top access opening 66. This can allow for linear, vertical removal of articles from the container 50 without the need for horizontal movement of the article to clear any obstruction.

Slots 118 can receive opposite side edges of an insert (not shown). The insert (e.g., a sheet of cardboard or plastic) can provide support for articles placed in the container 50. For example, it may be desirable to place an insert in the slots 118 between adjacent stacks of egg cartons placed within the container 50. The insert can reduce the potential for leaning and spilling of stacked egg cartons through front access opening 69. When egg cartons are removed from the container 50, the insert can be seen and removed from the container 50 to expose the adjacent stack of egg cartons.

With container 50 in the illustrated display configuration, the end walls 62 and 64 are secured to rear wall 60 to maintain the container 50 in the display configuration. In some embodiments, the end walls 62, 64 and rear wall 60 are secured to each other using releasable latches that include a finger 120 (FIG. 17) that can be secured within a recess (not shown) extending inwardly from side 76 of end walls 62, 64. The latches can be released to move the end walls 62, 64 and rear wall 60 relative to bottom wall 54.

Referring to FIG. 19, by providing the continuous access openings 66 and 69 free of any obstructions, a user, such as a customer, can freely pick articles 114 from either the top or side of the container 50 in the directions of arrows 122 and 124 with relative ease. Additionally, when filling the container 50 with articles 114, relatively little or, in some embodiments, even no space needs to be provided within the container volume 105 to allow for manipulation of the article 114 to clear a lip or support member that interrupts access through the access openings 66 and 69 when removing the article 114 from the container 50.

Referring to FIGS. 20 and 21, side and front section views, respectively, of the container 50 in the collapsed configuration are shown. In the collapsed configuration, the walls 52, 54, 58, 60, 62 and 64 are stacked one on top of the other with end wall 62 located at the top of the stack 126 and bottom wall 54 located at the bottom of the stack 126. Each of the walls 52, 58, 60, 62 and 64 are connected to the bottom wall 54, although front wall 58 and top wall 52 are not directly connected to the bottom wall 54. Instead, referring particularly to FIG. 20, front wall 52 is connected to bottom wall 54 through top wall 52 and rear wall 60 and joints A, B and C. Referring to FIG. 21, each end wall 62 and 64 is connected directly to the bottom wall 54 through their respective joints D and E. Other variations are possible. For example, the container 50 can be constructed such that bi-fold member 75 rests on top of stack 126. In some embodiments, the container 50 collapses to a height H of between about two inches to about six inches, such as about four inches.

Referring to FIGS. 22A-22I, a method of reconfiguring the container 50 between the enclosed configuration (FIG. 22A), the display configuration (FIG. 22F) and the collapsed configuration (FIG. 221) is illustrated. Referring to FIG. 22A, each of the walls 52, 54, 58, 60, 62, 64 are in their respective closed position with the container 50 in the enclosed configuration. To provide side access opening 69, front wall 58 is moved relative to the bottom wall 54 at joint A as shown by FIGS. 22B-22D. The front wall 58 can be rotated at joint A until the front wall 58 rests atop and adjacent to top wall 52 with sides 128 and 130 facing each other. With front wall 58 resting atop top wall 52, side access opening 69 is provided.

To provide top access opening 66, referring now to FIG. 22E, top wall 52 and front wall 58 are moved together relative to bottom wall 54 at joint B. Referring also to FIG. 22F, the top wall 52 and front wall 58 can be rotated at joint B until the front wall 58 rests adjacent the rear wall 60 with sides 132 and 134 facing each other. With front wall 58 resting adjacent rear wall 60, top access opening 66 is provided and the container 50 is in the display configuration.

Referring now to FIG. 22G, to place the container 50 in the collapsed configuration, the bi-folded member 75 (i.e., the rear wall 60, top wall 52 and front wall 58) is moved relative to the bottom wall 54 at joint C. Referring also to FIG. 22H, the bi-folded member 75 can be rotated at joint C until the rear wall 60 rests atop and adjacent the bottom wall 54 with sides 136 and 138 facing each other. Referring to FIG. 221, the end walls 62 and 64 are rotated about their respective axes D and E until they each rest on top of stack 126 forming the collapsed configurations described above with reference to FIGS. 20 and 21.

Although the walls 52, 54, 58, 60, 62, 64 are moveable due to joints A-E, as noted above, the end walls 62, 64 and rear wall 60 can be secured in their respective closed positions as shown by FIG. 22F, for example, using latches or other releasable securing structure (not shown) capable of securing the end walls 62, 64 to the rear wall 60. With the securing structure, the container 50 can be locked in the enclosed configuration. In some embodiments, other of the walls 52, 54, 58 may be secured in a respective closed position.

Container 50 can be formed to accommodate any desired number, size, shape and weight of article 114. In some embodiments, the container 50 may have a rated capacity of between about 100 and 500 pounds of product, such as up to about 180 pounds or up to about 250 pounds. The container 50 can be any desired size including having external dimensions of between about ten inches and about 40 inches in width such as about 24 inches in width, between about ten inches and about 40 inches in depth such as about 21 inches in depth, and between about ten inches and 40 inches in height such as about 23 inches in height. The container 50 can have internal dimensions of between about ten inches and about 40 inches in width such as about 23 inches in width, between about ten inches and about 40 inches in depth such as about 20 inches in depth, and between about ten inches and 40 inches in height such as about 20 inches in height. End walls 22 and 24 may be any desired thickness. In some embodiments, the end walls 22, 24 may be about ¾ inch thick or less, such as about ½ inch thick.

In another embodiment, a container 140 may have a depth D that is greater than its height H. Referring to FIG. 23, container 140 includes the features of container 50 with the addition of an added joint F at top wall 52. Referring to FIG. 24, the joint F provides a pivot between top wall sections 52a and 52b to allow top wall section 52a to rest adjacent the rear wall 60 in the display configuration without extending below the bottom wall 54. Container 140 can have external dimensions of between about eight inches and 15 inches in width, such as about 12 inches in width, between about eight inches and 15 inches, such as about 13 inches in height, and between about 12 inches and 24 inches in depth, such as about 23 inches in depth. In some embodiments, container 140 is sized to contain relatively heavy items, such as sugar, while not exceeding a pre-determined maximum weight capacity, such as about 200 pounds or less, such as 180 pounds or less, such as 100 pounds. Containers are also described in pending U.S. patent application Ser. No. ______, entitled “Configurable Display Container,” filed the same day as the instant application (attorney docket no. 058420-018), the details of which are hereby incorporated by reference as if fully set forth herein.

The above-described containers 50, 140 and handling apparatus 10 can be used at any desired type of facility including warehouses, manufacturing facilities, retail locations, such as department stores, mass merchants, home centers, electronics stores, drug stores, dollar stores, sporting goods stores, outlet stores, office supply stores, club stores, etc. For example, in the illustrated embodiments, handling apparatus 10 and container 50 may be used at a grocery store where product is stored at a storage location that is removed from a retail location. In this instance, it may be desirable to fill container 50 with “fast moving” items, such as eggs, for example, at a production facility. By “fast moving” items, we mean that relatively small percentage of items that drive a relatively large percentage of product movement from the storage location to the retail location for consumer purchase. Examples of fast moving items include, for example, sale items at certain price points, certain baked goods such as muffins, bagged produce such as bags of potatoes and bags of onions and certain granular products such as corn meal and flower.

By using handling apparatus 10 and container 50, a user can move more product to the shelf than could be done manually in a single run. It may be desirable to fill container 50 with items (e.g., promotional and seasonal items) at a regional distribution or consolidation center. Container 10, 60 may also be well-suited for handling bagged products such as cat litter, pet food, sugar, etc. by providing additional protection against bag rupture as the product is being placed on a display for purchase.

Referring now to FIG. 25-28, the above-described container 50 and handling apparatus 10 can be used in conjunction with in-store displays. FIG. 25 illustrates an example of an aisle display 150 that includes two containers 50a and 50b. Container 50a rests on an upper shelf 152 (e.g., between about three feet and about five feet, such as about four feet from the ground) that allows for placement of the container 50a the customer's eye level. Container 50b rests on a lower shelf 154 that is spaced from the ground (e.g., between about one foot to about three feet, such as about two feet), for example, to reduce the amount of bending a customer must do to reach an item supported on the lower shelf 154. The aisle display 150 includes a base 158 and wheels 160 that allow for re-positioning of the aisle displays, e.g., in the store. In some instances, the aisle display 150 may accept signage 162 or graphics that can convey a brand or “Great Price!” message. In some embodiments, signage 162 may be clipped or otherwise attached to end walls 62, 64 of the container 50b with the container in the display configuration. The aisle display 150 can be used, for example, to reinforce value pricing to price-sensitive shoppers and/or to place supplemental inventory in aisles 164 in support of promotional pricing.

Referring now to FIGS. 26 and 27, a single-sided display 170 includes multiple containers 50 resting on shelves 172. Display 170 may be suitable as an end-aisle display or as a seasonal display. Display 170 includes an uppermost, backstock level 174 that can be used to restock a lower level once all product is moved from a particular container 50. Use of backstock level 174 places a replacement container 50 full of product within relatively close proximity to an empty container 50. Once all product is removed from a particular container 50, the container 50 can be placed in the collapsed configuration as previously described and removed from the display 170. A replacement container 50 can be removed from the backstock level 174 and placed at the empty container's location on the display 170.

Referring to FIG. 28, a two-sided display 180 includes a front side 182 and a back side 184, each of the sides 182 and 184 including containers 50 and a backstock level 174. The two-sided display may be suitable for, e.g., soft drinks, bottled water, bagged potatoes and/or onions. It can be used across adjacent aisles or in open spaces within a store.

Where containers 50, 140 are used with in-store displays, such as those described above, it may be desirable to size the container 50, 140 to achieve a desirable viewing position for product within the container 50, 140. Additionally, in some embodiments, the containers 50, 140 are black in color, which can minimize the presence of the containers 50, 140 to consumers, which can emphasize the product. Alternatively, the containers 50, 140 may be any other suitable color such as red, white, blue, green, yellow, or any combination of the primary colors. In some instances, it may be desirable to match the container 50, 140 color with a store display color or for consistency with colors associated with a particular holiday, such as Christmas, Valentine's Day, Easter, Halloween, Thanksgiving, etc.

Referring now to FIGS. 29 and 30 a method 190 of container 50 handling, e.g., at a store location using the handling apparatus 10 is provided. The method 190 may be suitable to restock a store display, such as the display 7 of FIG. 1 and display 150 of FIG. 24. Referring to FIG. 28, the method includes a user 195 approaching a pallet 192 of stacked containers 50 at step 194. Containers 50 forming the pallet 192 may have been filled at an off-site location, such as at a production facility or at a warehouse, or the containers may have been filled on-site at a retail store location.

A side access opening 69 is provided to the container 50 that is to be transported from the pallet 192. As described above, the side access opening 69 is provided by pivoting front wall 58 at joint A relative to bottom wall 54. At step 196, the user 195 retrieves the handling apparatus 10 and approaches the pallet 192 of stacked containers 50. At a positioning steps 198 and 200, the container manipulation device 18 is raised vertically to align the interlocking member 24 with the device engagement structure 68 (FIGS. 9 and 10) of the container 50. The interlocking device 24 is moved horizontally to locate the engagement member 26 within the recess 80 and behind the entrance 87 to the U-shaped receiving portion 84 (see FIG. 10). At step 202, engaging member 26 is placed within the U-shaped receiving portion 84 and the container 50 is lifted to raise an edge 205 of the container off its underlying support surface 204 (FIG. 31). As the container 50 is lifted, the container 50 pivots about the engagement member 26 as described above with reference to FIG. 10. At removal steps 206, 208, 210 interlocking member 24 is retracted and the container 50 is pulled and positioned onto support member 20 with the interlocking member 24 still engaged with device engagement structure 68. At step 212, the container 50 is lowered for travel from the pallet 192 to a single-sided store display 170 at step 214. At this point, it should be noted that with the container 50 engaged with the interlocking member 24, the container guard 30 inhibits spilling of product from the container 50 by providing a temporary front wall barrier with front wall 58 of the container 50 repositioned at step 194. Additionally, by providing an at least somewhat transparent container guard 30, the user 195 can view the container 50 during the unload operation (see, e.g., step 198). In some embodiments, guides (not shown) such as markings on the container 50 and the handling apparatus 10 may be provided that aid the user in aligning the interlocking member 24 with the device engagement structure 68 of the container 50.

Referring now to FIG. 30, at step 216, the container 50 while still engaged with the interlocking member 24 is placed in its display configuration as described above by moving the top 52 and front 58 walls at joint B. At steps 218 and 220, an empty container 50′ is broken-down by placing the container 50′ in its collapsed configuration as described above. At step 222, the container 50 is moved vertically using the container manipulation device 18 to align the container with shelf 224 of the single-sided store display 170. At pushing steps 226 and 228, the container 50 is pushed along the support surface 22 and onto the shelf 224. The edge 205 of the container 50 is lowered onto the shelf 224 and the engaging member 26 is removed from the U-shaped receiving portion 84 at step 230.

As noted above, the device engagement structure 68 of the container 50 extends inwardly from a periphery of the bottom wall 54. This allows for exposure of the device engagement structure 68 when the container 50 is in the collapsed configuration. At step 232, the user 195 can engage a stack 234 of collapsed containers 50 and place the stack 234 atop collapsed container 50′ at steps 236 and 238. The user 195 can then engage the stack 234 including collapsed container 50′ to transport the stack 234, for example, to a location for a washing operation where the containers 50 can be washed and then reused and/or sent to a manufacturer or warehouse for refilling.

Referring now to FIG. 32, an automated container handling and product filling operation 240 includes an automated apparatus 242 having a product infeed 244, a container infeed 246 and a container/product outfeed 248. The automated apparatus 242 is capable of receiving containers 50 in their respective collapsed configurations through the container infeed 246 and automatically converting the containers 50 from the collapsed configuration to the display configuration as described above. Once the automated apparatus 242 has converted a container 50 to the display configuration, the automated apparatus 242 fills the container 50 with a pre-selected amount of product 250, such as soda cans or packages of soda cans, introduced to the automated apparatus 242 through product infeed 244 through one or both of the side access opening 69 and top access opening 66 of the container 50. Once the container 50 is filled with product 250, the automated apparatus 242 converts the container 50 from the display configuration to the enclosed configuration as described above and the filled containers 50′ are sent through the container/product outfeed 248.

In some embodiments, product is unitized by arranging the product in a pattern for placement within a container 50 as the pre-arranged unit. Referring to FIG. 32, packages 260 of soda, such as a cola, are arranged in a 4×4 unit 262. The unit 262 has be pre-determined so that the unit 262 can be placed in a container 50 and also so that the brand 264 is readily visible to a customer with the container 50 in the display configuration. In some instances, the unit 262 may be placed in a container 50 one row 266 or one column 268 at a time. In other instances, individual packages 260 may be placed in the container. Unitization of the product 260 and/or placement of the product 260 in the container may occur manually or automatically, for example, using apparatus 242 (FIG. 31).

In instances where the container 50 includes a lock, the automated apparatus 242 can lock the container 50 in the enclosed configuration. In some instances, the containers 50 may be washed or cleaned prior to introducing the containers 50 to the automated apparatus 242. In some instances, it may be desirable to arranged the containers 50, for example, to stand on their respective rear walls with the front opening 69 facing upward to fill the containers 50. This repositioning of the containers 50 can occur manually or automatically, for example, using apparatus 242. In some embodiments, once the container 50 is filled and converted to the enclosed configuration, the automated apparatus 242 stacks the filled containers 50 and the containers 50 are retrieved by an automated storage system, or stacks the containers 50, for example, on a pallet 252, such as that shown by FIG. 34. Referring to FIG. 34, the pallet 252 can be of any desired dimension, such as about 24 inches in width, about 21 inches in depth and about 23 inches in height. Height H of the stack of containers 50 including pallet 252 can be between about two feet and about ten feet, such as about eight feet.

It should be noted that while pallet 252 is shown supporting containers 50 having the same or similar product, the pallet 252 may carry containers 50 having different product types to form a “mixed” pallet. Furthermore, apparatus 242 above may fill certain containers 50 with a first product and other containers 50 with a second product that is different from the first product.

A number of detailed embodiments have been described. Nevertheless, it will be understood that various modifications may be made. For example, the containers 50 may include pallet structures, e.g., at the bottom of the containers that allow a handling apparatus, such as a forklift, to engage an underside of the container to lift the container from a shelf or off the ground. Additionally, the containers 50 may include stacking structures, such as ribs extend from the underside of the containers and mating grooves formed in the tops of the containers. The stacking structures can provided added stability when the containers are stacked one on top of the other. Accordingly, other embodiments are within the scope of the following claims.

Claims

1. A method for product handling, comprising:

filling a reusable container at a facility with a pre-selected amount of product, the container being sized and configured for display at a retail location and including a set of joined walls where some of the walls are configured to move relative to a bottom wall of the container to convert between an enclosed configuration enclosing an internal volume and a display configuration providing a side access opening and a top access opening to the internal volume such that the side and top access openings allow product to be removed from the container;

converting the container to the enclosed configuration by closing at least one of the top and side access openings to the container through which the container was filled with the pre-selected amount of product by moving at least one wall of the set of joined walls of the container relative to the bottom wall of the container; and

transporting the container in its enclosed configuration to the retail location.

2. The method of claim 1 further comprising locking the container in the enclosed configuration.

3. The method of claim 1 further comprising converting the container from a collapsed configuration where the joined walls are folded over the bottom wall to form a layered stack of walls to the display configuration.

4. The method of claim 3, wherein the step converting the container from the collapsed configuration to the display configuration occurs before the step of filling the container.

5. The method of claim 4, wherein the step of converting the container from the collapsed configuration to the display configuration is automated.

6. The method of claim 5, wherein the step of filling the container is automated.

7. The method of claim 6, wherein the step of converting the container to the enclosed configuration is automated.

8. The method of claim 3, wherein the step of converting the container from the collapsed configuration to the display configuration is manual.

9. The method of claim 1 further comprising stacking the container on a pallet prior to transporting the container.

10. The method of claim 1 further comprising placing the container in a storage system.

11. The method of claim 1 further comprising converting the container from the enclosed configuration to the display configuration at the retail location to provide the side access opening and the top access opening.

12. The method of claim 11 further comprising placing the container on a display at the retail location with the container in the display configuration, the product being exposed for viewing and picking by a customer through the top and the side access openings of the container.

13. The method of claim 12, wherein the display comprises an end-aisle display, an aisle display or a double-sided display.

14. The method of claim 12 further comprising attaching a sign to the container.

15. The method of claim 12 further comprising converting the container to a collapsed configuration where the joined walls are folded over the bottom wall to form a layered stack of walls after the product is removed from the container with the container on the display.

16. The method of claim 15 further comprising transporting the collapsed container from the retail location to the facility.

17. The method of claim 1 further comprising cleaning the container prior to the step of filling the container.

18. The method of claim 1, wherein the facility is a production facility, a distribution center or a consolidation center.

19. The method of claim 1, wherein the retail location is a supermarket or a club store.

20. The method of claim 19, wherein the step of filling the container includes filling the container with fast moving product.

21. The method of claim 1 wherein the step of filling the container includes positioning the product in the container such that a product brand name is viewable through at least one of the side and top access openings with the container in the display configuration.

22. The method of claim 1, wherein the facility is an off-site facility that is geographically removed from the retail location.

23. The method of claim 1, wherein the facility is an on-site facility that is connected to the retail location.

24. A method for displaying a product for retail sale, the method comprising:

converting a reusable container from a collapsed configuration where walls of a set of joined walls are folded over a bottom wall of the container to form a layered stack of walls to a display configuration by moving walls of the set of joined walls relative to the bottom wall, the container being sized for placement on a shelf of a display with the container in the display configuration;

filling the container at a facility with a pre-selected amount of product for retail sale with the container in the display configuration; and

converting the container to an enclosed configuration where the set of joined walls enclose the pre-selected amount of product.

25. The method of claim 24 further comprising transporting the container in its enclosed configuration to a retail location.

26. The method of claim 24 further comprising locking the container in the enclosed configuration.

27. The method of claim 24, wherein the step of converting the container from the collapsed configuration to the display configuration is automated.

28. The method of claim 27, wherein the step of filling the container is automated.

29. The method of claim 28, wherein the step of converting the container to the enclosed configuration is automated.

30. The method of claim 24, wherein the step of converting the container from the collapsed configuration to the display configuration is manual.

31. The method of claim 24 further comprising converting the container from the enclosed configuration to the display configuration at a retail location to provide a side access opening and a top access opening to an interior volume of the container.

32. The method of claim 31 further comprising placing the container on a display at the retail location with the container in the display configuration, the product being exposed for viewing and picking by a customer through the top and the side access openings of the container.

33. The method of claim 32, wherein the display comprises an single-sided display, an aisle display or a double-sided display.

34. The method of claim 32 further comprising attaching a sign to the container.

35. The method of claim 32 further comprising converting the container to the collapsed configuration where the joined walls are folded over the bottom wall to form a layered stack of walls after the product is removed from the container with the container on the display.

36. The method of claim 32, wherein the retail location is a supermarket or a club store.

37. The method of claim 24 further comprising cleaning the container prior to the step of filling the container.

38. The method of claim 24, wherein the facility is a production facility, a distribution center or a consolidation center.

39. The method of claim 24 wherein the step of filling the container includes positioning the product in the container such that a product brand name is viewable through at least one of the side and top access openings with the container in the display configuration.

40. A method of handling an item, the method comprising:

filling a reusable container at a facility with a pre-selected amount of items with the container in a display configuration, the container including a set of joined walls where some of the walls are configured to move relative to a bottom wall of the container to convert between an enclosed configuration enclosing an internal volume and the display configuration providing a side access opening and a top access opening to the internal volume such that the side and top access openings allow the items to be removed from the container; and

converting the container from the display configuration to the enclosed configuration by closing the top and side access openings by moving at least two joined walls of the set of joined walls of the container relative to the bottom wall of the container.

41. The method of claim 40 further comprising locking the container in the enclosed configuration.

42. The method of claim 40 further comprising converting the container from the enclosed configuration to the display configuration by moving the at least two joined walls of the set of joined walls of the container relative to the bottom wall of the container.

43. The method of claim 42 further comprising removing the items from the container through at least one of the top and side access openings.

44. The method of claim 43 further comprising converting the container from the display configuration to a collapsed configuration where the walls of the set of joined walls are folded over the bottom wall to form a layered stack of walls.

45. The method of claim 40, wherein the step of converting the container from the display configuration to the enclosed configuration is automated.

46. The method of claim 45, wherein the step of filling the container is automated.

47. The method of claim 40, wherein the step of converting the container from the display configuration to the enclosed configuration is manual.

48. The method of claim 40 further comprising placing the container on a display at a retail location with the container in the display configuration, the items being exposed for viewing and picking by a customer through the top and the side access openings of the container.

49. The method of claim 48, wherein the retail location is a supermarket, a club store, a department store or a mass merchant.

50. The method of claim 40, wherein the facility is a production facility, a distribution center or a consolidation center.