Merchandiser Assembly

Abstract

A merchandiser assembly includes a base and a plurality of support hoops having support arms and a divider arm, wherein the support arms may be secured adjacent to the base. The hoops may define a gap formed between the hoops for containing rolled articles from movement in a transverse direction. The merchandiser assembly may also include a plurality of gate assemblies located on the support hoops for further containing rolled articles from movement in a direction substantially perpendicular to said traverse direction.

Description

CROSS REFERENCES TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patent application Ser. No. 11/201,903 filed Aug. 11, 2005 and entitled “MERCHANDISER ASSEMBLY,” which claims priority to and the benefit of U.S. Provisional Application No. 60/601,096 filed Aug. 12, 2004. The present application claims priority to and the benefit of both U.S. patent application Ser. No. 11/201,903 and U.S. Provisional Application No. 60/601,096, and the disclosure of each is incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates to an assembly for transporting and displaying rugs.

BACKGROUND OF THE INVENTION

In the rug industry, manufacturers design and produce rugs for shipment to distributors and/or vendors. Once produced, it is desired that the rugs are packaged in a manner to allow easy loading/unloading of the rugs onto/off of a truck. In the past, manufacturers would roll the rugs and place them lengthwise on pallets. The problem with this approach was that pallet loaders or forklifts had difficulty accessing the pallet and loading the pallet full of rugs on the truck. To solve this problem, manufacturers began using open top merchandiser assemblies so that rugs could be stood on end (e.g. vertically) within the cage of the assembly. However, these merchandiser assemblies proved to be weak and often failed due to the weight of the heavy stacked rugs. In addition, as vendors desired to display rugs in the same assemblies in which the rugs were shipped, stronger, more functional assemblies were needed.

As such, there is a need for durable merchandiser assemblies configured to secure a number of rugs during transport and display.

SUMMARY OF THE INVENTION

Accordingly, the present invention is intended to address and obviate problems and shortcomings and otherwise improve previous merchandiser assemblies.

In one embodiment, a merchandising assembly includes a base and a plurality of support hoops that include support arms and a divider arm, wherein the support arms are secured to the base and wherein a plurality of gaps are defined between the support hoops for containing rolled articles from movement in a traverse direction. The assembly further includes a plurality of gate assemblies, the gate assemblies including at least one wing hingedly connected to a center section, wherein the gate assemblies are located on the divider arms of the support hoops for containing a rolled article from movement in a direction substantially perpendicular to said traverse direction. The at least one wing of said gate assemblies is capable of bending from a substantially flat configuration in an upward or downward direction, wherein when the wing is in a substantially flat configuration, the rolled article is contained from movement in a direction substantially perpendicular to the transverse direction, and when the wing is bent in an upward or downward direction, the rolled article is not contained from movement in a direction substantially perpendicular to the transverse direction.

In another embodiment, a merchandising assembly includes a base and a plurality of support hoops that include support arms and a divider arm, wherein the support arms are secured to the base and wherein a plurality of gaps are defined between the support hoops for containing rolled articles from movement in a traverse direction. The assembly further includes a plurality of gate assemblies, the gate assemblies including at least one wing hingedly connected to a center section, wherein the plurality of gate assemblies are located on the divider arms of the support hoops for containing the rolled article from movement in a direction substantially perpendicular to the traverse direction. The plurality of gates are capable of hinged movement from a clearance position to a support position, wherein the gate assemblies are oriented in clearance position when the at least one wing is positioned in an upward or downward orientation, and the gate assemblies are oriented in a support position when the at least one wing is positioned in a substantially flat orientation and supports at least a portion of the weight of the rolled article in an upright orientation.

Still other embodiments, combinations and advantages will become apparent to those skilled in the art from the following descriptions wherein there are shown and described alternative illustrative embodiments of this invention for illustration purposes. As will be realized, the invention is capable of other different aspects, objects and embodiments all without departing from the scope of the invention. Accordingly, the drawings and description should be regarded as illustrative and illustrative in nature only and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

It is believed that the present invention will be better understood from the following description taken in conjunction with the accompanying drawings in which:

FIG. 1 is an exploded perspective view of a merchandiser assembly in accordance with one illustrative embodiment of the present invention;

FIG. 2 is a perspective view of the assembled merchandiser assembly of FIG. 1 with a rug secured therein;

FIG. 3 is a perspective view of a merchandiser assembly in accordance with another illustrative embodiment of the present invention; and

FIG. 4 is a view of a portion of the illustrated embodiment of FIG. 3, showing a portion of a support hoop with attached gate assemblies.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring to the drawing figures in detail, wherein like numerals indicate the same elements throughout the drawing figures, FIG. 1 illustrates an exploded view of merchandiser assembly 10 according to one illustrative embodiment of the present invention. As illustrated, merchandiser assembly 10 may comprise base 12, a pair of base arm mounts 20, a plurality of support hoops 30, rest rail 40 (or rail segments 41, as further detailed herein) and rear rail 50. As discussed later herein, and illustrated in FIGS. 2 and 3, these and other components can be fitted together to form merchandiser assembly 10 and 110 for transporting and displaying rugs 17 and other articles of various sizes in a convenient and space efficient manner. Moreover, while the present invention is described as being used with transporting and displaying rugs, other products may be used in association with the present invention.

Referring to FIGS. 1-3, base 12 of merchandiser assembly 10 and 110 is illustrated as comprising a pallet type design. More particularly, pallet 12 may comprise a plurality of spaced slats 14 secured to frame 16. The design allows vertically displayed rugs to rest in between spaced slats 14. For example, as illustrated in FIG. 2, corner 18 of rolled rug 17 may rest between slats 14a and 14b. This design may assist in keeping the rolled rugs 17 in a vertical orientation. As illustrated in FIG. 3, other embodiments may further include a plurality of lower gripping rails 15 that may be attached perpendicular to spaced slats 14. This design may also assist in keeping a rolled rug in a vertical position. Pallet design is also useful as it provides channels 19 for accepting the forks of a forklift and/or a pallet loader for transporting the merchandiser assembly about a display surface or from/to a transport truck. Of course any base may be used such as, for example, a base comprising a solid sheet in place of the slats with a plurality of holes cut therein so as to accept and secure a rolled rug.

In order to secure support hoops 30 to base 12, a pair of base arm mounts 20 may be used. As illustrated, each base arm mount 20 may comprise a generally U-shaped configuration with a number of support hoop apertures 22 therein. In addition, base arm mount 20 may comprise mount lip 24 and upper and lower prop lips 26a and 26b. Although a pair of base arm mounts 20 are illustrated, any number of base arm mounts 20 may be used.

Base arm mount 20 may be secured to base 12 and may be configured to telescopingly receive support hoops 30. More particularly, mount lip 24 of base arm mount 20 may be located on slat 14 of base 12 and then may be secured thereto by drilling fasteners through holes 28 located in mount lip 24 and into slat 14 of base 12. As illustrated in FIG. 2, base arm mounts 20 may be secured to base 12 at the outer edge thereof. However, it is contemplated that base arm mounts 20 may be secured at any location on the base. In addition, it should be understood that base arm mounts 20 may comprise any apparatus or assembly configured to receive and maintain support hoops 30 in a desired position.

As illustrated, merchandiser assembly may also comprise a plurality of support hoops 30. Between these support hoops 30, a gap may be formed so that rugs may be inserted and maintained during transport and/or display. More particularly, rugs or other rolled articles positioned within the gaps are contained from movement in a side-to-side (traverse) direction. While rugs may be able to move forward and backward within the gaps, such rugs are contained sufficiently to prevent the rugs from falling to the ground in a side-to-side direction.

Each support hoop 30 may comprise two support arms 32 and a divider arm 34 to form a generally U-shaped configuration or hoop. Support arms 32 and divider arm 34 may comprise individual components telescopingly fitted together, or in another embodiment, may comprise a single piece, such as a single post bent into a U-shaped configuration. Of course, in another embodiment “support hoops” may actually comprise a wall or other such divider for rugs or articles capable of containing the same. Accordingly, the use of the term “hoop” is not intended to connote a structural limitation. Upper and lower ends 32a and 32b of support arms 32 or hoop 30 may comprise openings 36 and 38 for accepting one or more fasteners discussed below.

To assist in the vertical positioning of the articles (e.g., rugs) within the gaps in a side-to-side direction, some embodiments (e.g., FIG. 3) may further include one or more lower positioning member 31 to connect between support arms 32 of support hoop 30. Lower positioning member 31 may cooperate with divider arm 34 to maintain an article in a vertical orientation by giving side support to the article both at the top of support hoop 30 and near base 12. However, embodiments of merchandiser assembly 10 and 110 need not include lower positioning member 31. Further, to assist in the vertical positioning of the articles in a front-to-back direction, some embodiments (e.g., FIG. 3) also may include one or more gate assembly 300 located along divider arm 34. Gate assembly 300 may work alone or may cooperate with lower gripping rails 15 to maintain an article in a vertical orientation by giving front and/or back support to the article at base 12 and/or the top of support hoop 30. As shown in FIG. 3, gate assembly 300 can be bent in an upward direction to allow articles to be placed within or removed from the gaps (between support hoops 30 or between support hoops 30 and adjacent gate assemblies 300), and bent back to a substantially flat configuration to support and/or contain articles in a vertical position within the gaps between support hoops 30. However, as shown in FIGS. 1 and 2, embodiments of merchandiser assembly 10 need not include lower gripping rails 15, nor gate assemblies 300.

Referring to FIGS. 3 and 4, gate assembly 300 may comprise a substantially flat elongated shape that is capable of being deformed in an upward or downward direction. However, any shape or configuration may be utilized. Gate assembly 300 can be constructed of any material now or hereinafter know in the art that is capable of being bent, but also capable of holding a particular shape or bent configuration. Non-limiting examples include steel, aluminum, tin and other various metals, plastics, polymers and combinations thereof. In the non-limiting illustrated embodiments, gate assembly 300 comprises two wings 302 hingedly connected to a center section 304, and two apertures 306 having stops 308 defined therein. Center section 304 can be located over divider arm 34 with wings 302 extending out from center section 304, at least partially spanning the gap between support hoops 30. Apertures 306 are located adjacent to center section 304. Because apertures 306 remove a section of material across the width of gate assembly 300, the portions of gate assembly 300 where apertures 306 are located has a weaker bend modulus as compared to other portions of gate assembly 300. Accordingly, a user can bend and re-bend gate assembly 300 at that particular location from a substantially flat configuration to various upward and/or downward configurations, or from various upward and/or downward configurations to substantially flat configurations. However, other embodiments of gate assembly 300 may bend due to a predetermined thinner or weaker point in the gate assembly, and therefore need not include apertures 306. Yet other embodiments may have gate assemblies that utilize a pivot or hinge to connect the at least one wing with the center section, thus allowing the user to position the gate assemblies from substantially flat configurations to various upward and/or downward configurations.

Gate assembly 300 may also include stops 308 to not allow wings 302 from bending past a substantially flat configuration in a downward direction or bending past a substantially flat configuration in a upward direction. The non-limiting embodiments of FIGS. 3 and 4 show gate assemblies 300 including stops 308 that comprise protrusions that extend into apertures 306 and rest against divider arm 34 when gate assembly is in a substantially flat orientation, and therefore do not allow wings 302 to bend any further in a downward direction past the substantially flat orientation. Other non-illustrated embodiments may comprise gate assemblies 300 that include stops 308 that do not allow wings 302 to bend any further in an upward direction past the substantially flat orientation. However, other non-illustrated embodiments may comprise gate assembly 300 that does not include stops 308.

Accordingly, it should be understood that gate assembly 300 may be any device that can be secured to merchandiser assemblies 10 and 110 discussed herein capable of hingedly and selectively moving at least one wing 302 from a clearance position where an article can be removed from the merchandiser assembly to a support position wherein at least a portion of the gate assembly supports at least a portion of the weight of an article to be displayed by the merchandiser assembly in an upright orientation. A clearance position corresponds to wing 302 bent, deformed or positioned (through utilization of a hinge or otherwise) in a upward or downward orientation. A support position corresponds to wing 302 positioned in a substantially flat orientation, wherein an article may rest on support surface 310 of wing 302. For example, as illustrated in the non-limiting embodiment of FIG. 4, gate assembly 300 can be oriented to have both wings located in a clearance position (320), to have one wing oriented in a clearance position and one wing in a support position (330), or to have both wings located in a support position (340). As further depicted in FIG. 3, an article (not shown) positioned in location 350 of merchandiser assembly 110 would be surrounded by four wings, all positioned in a support orientation. Accordingly, an article positioned in location 350 would have four support surfaces to rest against, therefore being supported in an upright position. An article (not shown) positioned in location 360 of merchandiser assembly 110 would be surrounded by four wings, all in a clearance position. Accordingly, an article positioned in location 350 could be removed from merchandiser assembly 110.

In some embodiments (e.g., FIGS. 3 and 4), gate assembly 300 may be a separately manufactured part from divider arm 34, and attached to divider arm 34 through the utilization of any type of fastener. In other embodiments, gate assembly 300 may be a separately manufactured part from divider arm 34, and attached to divider arm 34 through welding or the utilization of an adhesive. In yet other embodiments, gate assembly 300 and divider arm 34 may comprise a one-piece construction.

Referring back to the embodiments of FIGS. 1 and 2, merchandiser assembly 10 comprises four support hoops 30. However, any number of support hoops 30 may be secured to any desired size base. For instance, the non-limiting embodiment shown in FIG. 3 has seven support hoops 30. As previously discussed, support hoops may be telescopingly received in base arm mounts 20 at support hoop apertures 20. More particularly, lower end 32b of support hoop 30 may be received in upper and lower apertures 22a and 22b of base arms mounts 20 and be secured thereto with, for example, a fastener, or other locking arrangement. In one embodiment, lower end 32b of support hoop 30 may rest on base 12 (e.g. FIGS. 1-3). In another embodiment, lower end 32b of support hoop 30 may rest on support arm mount 20. In addition, aside from resting on base 12, lower ends 32b of support hoops 30 are similarly stabilized against upper and lower prop lips 26a and 26b of base arm mounts 20.

As illustrated in FIG. 3, support hoops 30 may also include reinforcing members 33. In some embodiments, reinforcing members 33 may be included on the support hoops located on the outside perimeter of base 12 (e.g., FIG. 3), or in other embodiments, located on other support hoops located at other various positions (e.g., not located on the outside perimeter of base 12). Because of this design, merchandiser assembly 10 can support heavy loads, such as rolled rugs contained between respective support hoops 30.

Merchandiser assembly 10 may also comprise a rest rail 40 configured to be removably secured to one or more support arms 30. More particularly, rest rail 40 may comprise upper and lower rail apertures 42 and 44 each configured to be secured to support arm openings 36, depending on the desired orientation of the rest rail 40. The rest rail 40 may be configured to provide a surface for one or more vertically rolled rugs 17 or other articles to rest against (see FIG. 2). In addition, rest rail 40 may be removable so as to load and unload merchandiser assembly. Of course, a number of components or combinations of components can be used to provide a surface to prevent or inhibit movement of the rugs in a forward direction. Accordingly, use of the term “rail” should not be limited in structure as other such components (e.g., divider, barrier, etc.) can be used. For example, as illustrated in the embodiment of FIG. 3, the rest rail may comprise a plurality of rest segments 41. Rest segments 41 may work together to function as a rail, or may work individually to allow articles to be removed from a single gap between support arms 32.

In use, rest rail 40 or rest segments 41 may be attached across one or more gap so as to contain rolled articles from movement in a front-to-back direction discussed above. Such containment of forward and/or backward movement can mean prevention of the rugs from falling forward or backward (depending on the location of the rest rail) to the ground. Limited front-to-back movement discussed above may be appropriate when the merchandiser is not full.

It is a feature of some embodiments that rolled rugs 17 of various sizes may be accommodated by switching the rest rail from tall and short orientations. By way of example, if the rolled rug 17 of FIG. 2 was a 8×11 rug (e.g. 8 foot wide, and therefore, 8 foot tall in the merchandiser assembly 10), rest rail 40 may be configured in its tall orientation as shown (e.g. rail apertures 44 aligned and secured to support arm openings 36) so that a taller rolled rug does not fall out of merchandiser assembly because rest surface 46 is higher. However, if a 6×9 rug were inserted into the merchandiser assembly 10 of FIG. 2 (e.g., an assembly with the rest rail in the tall orientation), the rug may fall under rest rail 40 and onto a display surface. Accordingly, rest rail 40 may be switched to its lower orientation (e.g. rail apertures 42 aligned and secured to support arm openings 36) to provide a support surface 46 for smaller sized rugs. It is contemplated that if larger rugs are to be transported or displayed, the rest rail 40 will be secured in its tall orientation (e.g., FIG. 2).

It should be understood that although rest rail 40 is illustrated as being fixedly secured to two support hoops 30 (e.g. rail apertures 42 or 44 aligned and secured to support arm openings 36), a number of alternative embodiments are contemplated. For example, rest rail 40 may be configured to be telescopingly received by support hoops 30 such as at the outermost support hoops, between adjacent support hoops or intermittent support hoops. Such may be accomplished by providing apertures within support hoops and securing rest rail therein through snap locks or other convention locking devices. In addition, although rest rail 40 and rest segments 41 are illustrated as being located toward the outer end of support hoops 30, any type of rest rail may be located at any position along support hoops and/or base.

Rear rail 50 is illustrated and configured to prevent one or more rolled rugs 17 from falling out of the rear of the merchandiser assembly 10. As illustrated, rear rail 50 may be configured to be fixedly secured to one or more support hoops 30 such as at openings 36. This embodiment may be desired when rugs are being transported and increased stability of the merchandiser assembly 10 is preferred. However, in another embodiment, rear rail 50 may be selectively removable from one or all support hoops 30. Such embodiment may be desired when the merchandiser assembly 10 is used to display rugs. More particularly, if a customer desires to purchase a rug displayed in the merchandiser assembly 10, a vendor can simply remove rear rail 50 and remove the rolled rugs from the gap defined by adjacent support hoops (assuming the desired rug is not first in line). Once removed, vendor can reattach rear rail 50. In such embodiment, the rear rail 50 may be secured to one or more support hoops through a snap and lock assembly, or other locking arrangement. The rear rail 50 may be configured to be removable from all of the support hoops 30 or simply between adjacent support hoops, such as 30a and 30b (see FIG. 2). Such may be accomplished by, for example, providing hinges between adjacent rear rail pieces and corresponding to the support hoops 30. Of course, as discussed, it is contemplated that rest rail 40 may similarly be removed to load and unload rugs in the merchandise assembly.

One of the aspects of the present invention, as previously discussed, is that the merchandiser assembly can be used to transport and display rolled rugs. It is contemplated that merchandiser assembly 10 can be modular so that each can be individually broken down and shipped to a vendor and/or manufacturer. For example, if a manufacturer has rugs to be shipped, the broken down merchandiser assembly can be delivered to the manufacturer in a packaged container. The manufacturer may then use its own base (e.g., a pallet where applicable or desired) and construct the merchandiser assembly as discussed above. The manufacturer may then load the merchandiser assembly full of rugs for transport to a vendor. Because the merchandiser assembly is designed to adapt to a conventional pallet, the constructed assembly with pallet base may be loaded onto a truck and shipped to a vendor. Once received by the vendor, the vendor may unload the merchandiser assembly from the truck and place the assembly directly in a display room, thus eliminating the step of unloading each individual rug and transferring the same to a display rack. In addition, if a vendor has rugs from a manufacturer that does not utilize the merchandiser assembly, the same broken down packaged merchandiser assembly can be shipped to the vendor, assembled and use solely to display any number of rugs. As such, the present invention provides a stable assembly for transporting and displaying rugs.

The foregoing description of the various embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many alternatives, modifications and variations will be apparent to those skilled in the art of the above teaching. For example, the merchandiser assemblies in accordance with the present invention may display rugs of varying sizes and shapes in a variety of different arrangements and can include bases, arm base mounts and support hoops organized in a variety of arrangements. Accordingly, while some of the alternative embodiments of the merchandiser assembly have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. Accordingly, this invention is intended to embrace all alternatives, modifications and variations that have been discussed herein.

Claims

1. A merchandiser assembly comprising:

a base;

a plurality of support hoops comprising support arms and a divider arm, wherein said support arms are secured to said base and wherein a plurality of gaps are defined between said support hoops for containing at least one rolled article from movement in a traverse direction; and

a plurality of gate assemblies comprising at least one wing hingedly connected to a center section, wherein said plurality of gate assemblies are located on said divider arms of said support hoops for containing said at least one rolled article from movement in a direction substantially perpendicular to said traverse direction, wherein said at least one wing of said gate assemblies is capable of bending from a substantially flat configuration in an upward or downward direction, wherein when said wing is in a substantially flat configuration said at least one rolled article is contained from movement in a direction substantially perpendicular to said transverse direction, and wherein when said wing is bent in an upward or downward direction said at least one rolled article is not contained from movement in a direction substantially perpendicular to said transverse direction.

2. The merchandiser assembly of claim 1, wherein said gate assemblies further comprise at least one aperture.

3. The merchandiser assembly of claim 2, wherein said gate assemblies further comprise at least one stop.

4. The merchandiser assembly of claim 1, further comprising a rest rail secured across said plurality of support hoops, or a plurality of rest segments secured on said plurality of support hoops.

5. The merchandiser assembly of claim 1, wherein said support arms of said support hoops are removeably secured to said base.

6. The merchandiser assembly of claim 1, wherein said merchandiser assembly further comprises at least one base arm mount having a plurality of apertures configured to removeably receive said support arms of said support hoops.

7. The merchandiser assembly of claim 6, wherein said support arms of said plurality of said support hoops are removeably secured to said base arm mount.

8. The merchandiser assembly of claim 6, wherein said base arm mount further comprises a mount lip configured to secure said base arm mount to said base.

9. The merchandiser assembly of claim 1, wherein said base is a pallet.

10. The merchandiser assembly of claim 1, wherein said base comprises channels configured to receive forks of a forklift.

11. The merchandiser assembly of claim 1, wherein said rolled articles are rugs.

12. A merchandiser assembly comprising:

a base;

a plurality of support hoops comprising support arms and a divider arm, wherein said support arms are secured to said base and wherein a plurality of gaps are defined between said support hoops for containing at least one rolled article from movement in a traverse direction; and

a plurality of gate assemblies comprising at least one wing hingedly connected to a center section, wherein said plurality of gate assemblies are located on said divider arms of said support hoops for containing said at least one rolled article from movement in a direction substantially perpendicular to said traverse direction, wherein said plurality of gates are capable of hinged movement from a clearance position to a support position, said gate assemblies being oriented in clearance position when said at least one wing is positioned in an upward or downward orientation, and said gate assemblies being oriented in a support position when said at least one wing is positioned in a substantially flat orientation and supports at least a portion of the weight of said at least one rolled article in an upright orientation.

13. The merchandiser assembly of claim 12, wherein said gate assemblies further comprise at least one aperture.

14. The merchandiser assembly of claim 13, wherein said gate assemblies further comprise at least one stop.

15. The merchandiser assembly of claim 12, further comprising a rest rail secured across said plurality of support hoops or a plurality of rest segments secured on said plurality of support hoops.

16. The merchandiser assembly of claim 15, wherein said rest rail contains said rolled articles from movement in a direction perpendicular to said transverse direction, said rest rail comprising a rest surface and being adjustable between a tall and short orientation, wherein when said rest rail is in said tall orientation, said rest surface is at a greater distance from said base than when said rest rail is in said short orientation, so as to allow said rest rail to support rolled articles of multiple lengths.

17. The merchandiser assembly of claim 12, wherein said support arms of said plurality of said support hoops are removeably secured to a base arm mount.

18. The merchandiser assembly of claim 17, wherein said base arm mount further comprises mount lips configured to secure said base arm mount to said base.

19. The merchandiser assembly of claim 12, wherein said base is a pallet.

20. The merchandiser assembly of claim 12, wherein the gate assemblies are constructed of at least one of steel, aluminum, tin, other various metals, plastics and polymers.