The present invention is directed to an apparatus and method for storing articles in cells and more particularly to a system wherein the cells are selectively variable in size.
In article handling and storing systems, an array of cells is often employed for temporary holding of articles in a warehouse environment. This occurs in the distribution process between manufacturing and retail sales. Articles enter the warehouse and are placed in cells having a known location identifier, such as x columns across and y rows down in the array. The cells are typically of uniform width, height, and depth. The cell array is often constructed of a plastic such as vinyl in sheet form, or of a fabric. The cell array structure is sewn together. Alternatively, the structure can be assembled by heat-sealing or with adhesives. The sheet or fabric structure is lightweight and inexpensive.
The cell array structure has a flexible vertical panel on each side, left and right. The front and rear aspects are open. A plurality of shelves extends across between the vertical panels. The shelves are spaced apart vertically. Each shelf has a double floor sewn together, forming a pocket. A rigid plate is inserted into the pocket, which is then sewn closed. The plate can be any lightweight, inexpensive material, such as vinyl, PVC, ABS, Masonite, plywood, etc. The plate serves to stiffen and strengthen the shelves to hold the articles.
The cell array is top-supported, and hangs downward from a structural support or frame. Several cell arrays can be arranged one behind another, two or three deep. The cell array can be stationary, or can be hung on rollers to slide left and right so as to allow access to a second or third array hanging behind the first array. Handcarts are used to convey articles from one area to another. Incoming products arrive and are sent to the cell array storage area by cart. Later, outgoing orders are taken by cart to shipping.
The articles are typically placed in totes, or trays of a predetermined size designed to fit into the cells. The totes are then placed into the cells. In this embodiment, the user is handling totes approximately 80% of the time. Articles do not always fit within the totes. Articles that are too large must be placed upon the floor, or in a special area. These exceptions occur approximately 20% of the time. Examples are bags of dog food or large items in boxes. Large articles are often placed upon the top of the cart. A heavy article is difficult to lift, may cause injury, and makes the cart top-heavy.
Accordingly, it would be desirable to provide a storage cell array system capable of accommodating both totes and articles of varying sizes, including bulky, heavy, and large articles, thereby avoiding the problems associated with the prior art.
In one aspect, a storage system with retractable cells is used in connection with storing and transporting articles. The storage system comprises a structural support. A cell array includes a left flexible vertical panel depending from the structural support. A right flexible vertical panel also depends from the structural support. The right vertical panel is generally parallel to the left vertical panel and spaced apart therefrom. A plurality of shelves extends transversely between the left vertical panel and the right vertical panel. The shelves are generally rigid. The shelves are spaced apart vertically by a predetermined space.
A left filament extends from a proximal end at the structural support to a distal end attached to a one of the plurality of shelves. A right filament extends from a proximal end at the structural support to a distal end attached to a one of the plurality of shelves. A plurality of left guide members are attached to the left vertical panel. Each left guide member is juxtaposed with one of the plurality of shelves. Each left guide member slidingly engages the left filament. A plurality of right guide members is attached to the right vertical panel. Each right guide member is juxtaposed with one of the plurality of shelves. Each right guide member slidingly engages the right filament.
Pulling means is provided for pulling the left filament and right filament upward. This is to raise the plurality of shelves upward. The left vertical panel and the right vertical panel will fold inwardly between the shelves in the manner of an accordion bellows. Thus, the space beneath the shelves will increase. The result is to receive an article beneath the shelves larger than the predetermined space.
In another aspect, a method is disclosed for retracting cells. This is used in a storage system for storing and transporting articles. The method comprises providing a structural support. Left and right flexible vertical panels are depending from the structural support. The vertical panels are spaced apart. A plurality of shelves extends transversely between the vertical panels. Spacing the shelves apart vertically by a predetermined space allows sufficient space to receive one of the articles.
Left and right filaments are extending from proximal ends at said structural support to distal ends. The distal ends attach to one of the plurality of shelves. The left and right filaments are for pulling upward.
In practice, the plurality of shelves will be raised upward by pulling the left and right filaments. This will increase space beneath the shelves by raising the shelves upward. The resulting space will thereby allow an article larger than the predetermined space to be received beneath the shelves.
In still another aspect, a storage system with retractable cells for storing and transporting articles is for use in connection with a structural support. The storage system comprises left and right flexible vertical panels. The panels are adapted for depending from the structural support. A plurality of shelves extends transversely between the left and right vertical panels. The plurality of shelves includes a lowermost shelf. The shelves are spaced apart vertically by a predetermined space.
Left and right filaments are each attached at a distal end to the lowermost shelf. The filaments extend upward to a proximal end adapted for attachment to one of the plurality of shelves above the lowermost shelf. Attachment means is provided for attaching the left and right filaments to one of the plurality of shelves.
In practice, the lowermost shelf will be lifted manually upward, to selectively raise at least one of the plurality of shelves upward. The left and right filaments will be attached to one of the shelves above the lowermost shelf with the attachment means. This is for increasing the space beneath the plurality of shelves so as to receive, below the lowermost shelf, an article larger than the predetermined space.
These and other aspects, objectives, features, and advantages of the disclosed technologies will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.
Describing now in further detail these exemplary embodiments with reference to the Figures as described above, it should be noted that the drawings presented herein are not to scale. A storage system with retractable cells 30 is used in connection with storing and transporting articles. The storage system 30 comprises a structural support 32. A cell array 34 is a single hanging column of cells, and includes a left flexible vertical panel 36 depending from the structural support 32. A suspending member 35 non-limitingly attaches the cell array 34 to the structural support 32. A right flexible vertical panel 38 also depends from the structural support 32. The left and right flexible vertical panels 36, 38 are attached at an upper end 37 to the structural support 32. The right vertical panel 38 is generally parallel to the left vertical panel 36 and spaced apart therefrom. A plurality of shelves 40 extends transversely between the left vertical panel 36 and the right vertical panel 38. The shelves 40 are generally rigid. The shelves 40 are spaced apart vertically by a predetermined space. The plurality of shelves 40 includes a lowermost shelf 58 having a front edge 60 and a rear edge 62. The left and right flexible vertical panels 36, 38 are attached at a lower end 39 to the lowermost shelf 58.
The structural support 32 includes upright columns 90 extending between opposite upper 92 and lower 94 ends. The structural support 32 can be a stationary framework or fixed support 82, as shown in
The cell array 34 is raised, lowered, and secured by right and left hangers, each hanger being attached at a distal end to the respective right and left panel lower end. As used herein, a “hanger” means any structure or means for raising, lowering, and/or securing the cell array of the storage system of the present invention. Non-limiting examples of hangers useful in the present invention are described below and include, without limitation, one or more filaments, one or more slings with our without attached filament(s), and wireformed clips used in conjunction with engaging members. In an embodiment, the one or more filaments may be secured using an attachment meand such as a hook and loop fastener.
In an embodiment, each hanger includes a filament. A left filament 42 extends from a proximal end 44 at the structural support 32 to a distal end 46 attached to a one of the plurality of shelves 40. A right filament 48 extends from a proximal end 50 at the structural support 32 to a distal end 52 attached to one of the plurality of shelves 40.
A plurality of left engaging members, or guide members 54 are attached to the left vertical panel 36. Each left guide member 54 is juxtaposed with one of the plurality of shelves 40. Each left guide member 54 slidingly engages the left hanger or filament 42. A plurality of right engaging members, or guide members 56 is attached to the right vertical panel 38. Each right guide member 56 is juxtaposed with one of the plurality of shelves 40. Each right guide member 56 slidingly engages the right hanger or filament 48. The left and right guide members are typically webbing sewn or attached to the left and right vertical panels 36, 38, respectively. However, any material can be used.
In an embodiment of the present invention, a left sling 64 has a front portion 66 attached to the lowermost shelf 58 adjacent the front edge 60 and a rear portion 68 attached to the lowermost shelf 58 adjacent the rear edge 62. The front 66 and rear 68 portions extend upward from the lowermost shelf 58 and converge at a left sling apex 70. The left filament distal end 46 is attached to the left sling apex 70. A right sling 72 has a front portion 74 attached to the lowermost shelf 58 adjacent the front edge 60 and a rear portion 76 attached to the lowermost shelf 58 adjacent the rear edge 62. The front 74 and rear 76 portions extend upward from the lowermost shelf 58 and converge at a right sling apex 78. The right filament distal end 52 is attached to the right sling apex 78. Thus, the front and rear portions of the left 64 and right 72 slings, being spaced apart, will stabilize the lowermost shelf against tipping.
A pulling means is provided for pulling the left filament 42 and right filament 48 upward. This is to raise the plurality of shelves 40 upward. The pulling means comprises an arcuate turning member 96 at the upper end 92 of the structural support 32. The left filament proximal end 44 extends over the arcuate turning member 96. The right filament proximal end 50 also extends over the arcuate turning member 96. The arcuate turning member 96 can comprises a system of pulleys 98, as shown in
The predetermined space is defined by the shelves 40 being spaced apart vertically. The predetermined space is typically sufficient to receive a tote (not shown), which is a tray used to store and transport articles in commerce. In practice, pulling the left filament 42 and right filament 48 upward will raise the shelves 40 upward. The shelves 40 may also be lowered downward. The left 36 and right 38 vertical panels will fold inwardly between the shelves 40 in the manner of an accordion bellows, thereby allowing the shelves 40 to be raised and lowered. Thus, the space beneath the shelves will increase, thereby allowing an article larger than a tote to fit beneath the shelves. The shelves 40 can be raised selectively by one cell, two cells, or any number of cells. The shelves 40 can be raised fully, as shown in
Turning now to
The cell array 134 is raised, lowered, and secured by hangers. The hangers include left 142 and right 148 filaments. The left filament 142 has a proximal end 144 a distal end 146. The right filament 148 has a proximal end 150 and a distal end 152. Each filament 142, 148 is attached at the distal end to the lowermost shelf 158. Storage system 130 differs from storage system 30 described above, in that the filaments 142, 148 extend upward to the proximal end, which is adapted for attachment to any one of the plurality of shelves 140 above the lowermost shelf 158. Attachment means is provided for attaching the left 142 and right 148 filaments to any one of the plurality of shelves 140. The attachment means 154 can take a variety of forms, for example: hook and loop fasteners; hooks and grommets; turn buttons; and snaps. The hook and loop fasteners, known as Velcro®, is preferred.
In practice, the lowermost shelf 158 will be lifted manually upward. This will selectively raise one or more of the plurality of shelves 140 upward. The left 142 and right 148 filaments will be attached to any one of the plurality of shelves 140 above the lowermost shelf 158 with the Velcro® attachment means 154. In this manner, space beneath the plurality of shelves 140 is increased so as to receive, below the lowermost shelf 158, an article larger than the predetermined space. Thus, articles that are too large to fit into a tote can be stored beneath the cell array on the structural support 32.
Referring now to
Storage system 230 differs from storage system 30 described above, in that the storage system 230 includes a first plurality of shelves 240 extending transversely between the right 238 and left 236 vertical panels. The first plurality of shelves 240 is spaced apart vertically by a first predetermined space 242 and has a first size cell 244.
A second plurality of shelves 246 extends transversely between the right 238 and left 236 vertical panels. The second plurality of shelves 246 is spaced apart vertically by a second predetermined space 248 and having a second size cell 250. The second predetermined space 248 is greater than the first predetermined space 242. The second size cell 250 is larger than the first size cell 244. Either one of the first or second plurality of shelves is disposed above the other plurality of shelves. The first plurality of shelves 240, having the first size cell 244, may be disposed uppermost in the cell array. The second plurality of shelves 246, having the second size cell 250, is then disposed lowermost in the cell array. This arrangement is shown in the drawings. Alternatively, The second plurality of shelves 246, having the second size cell 250, may be disposed uppermost in the cell array. The first plurality of shelves 240, having the first size cell 244, is then disposed lowermost in the cell array (not shown). In either case, the cell array 234 has a lowermost shelf 252 at the bottom.
Right and left hangers 254 are each attached at a distal end 256 to the respective right 238 and left 236 panel lower end 239. The right and left hangers 254 are typically wireformed clips, but can be made of any material, non-limitingly. Each clip 254 is preferably attached at the distal end 256 to the lowermost shelf 252 of the plurality of shelves 240, 246. Each clip 254 extends upward to a proximal end 258 having a hook 260.
Right and left engaging members 262 are attached to the right 238 and left 236 panels adjacent each of the plurality of shelves 240, 246. The right and left engaging members 262 engage the right and left hangers 254 respectively. The engaging members 262 selectively attach the hangers 254 to the panels 238,236 adjacent a selected shelf. The engaging members 262 further comprise loops 262 attached to the right 238 and left 236 vertical panels. The loops 262 may be webbing folded back on itself and sewn or attached to the panels. The loops 262 are juxtaposed with the shelves, on either side of each shelf. The loops 262 receive the clip hooks 260.
The first plurality of shelves is adapted to be selectively raised upward into a raised position, and lowered downward into a lowered position. In this manner, the first size cell may be selected or deselected, as desired. The second plurality of shelves is adapted to be selectively raised upward into a raised position, and lowered downward into a lowered position. In a similar manner, the second size cell may be selected or deselected, as desired. Receiving the clip hooks in the loops will selectively secure the shelves in the raised position.
The first and second plurality of shelves is adapted to be raised sufficiently so as to receive beneath the shelves an article larger than the second size cell. The right and left vertical panels are adapted to fold inward between adjacent shelves, thereby allowing the shelves to be raised upward or lowered downward.
It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
This application claims priority to U.S. Provisional Patent Application No. 62/212,295, filed on Aug. 31, 2015, the contents of which are incorporated herein by reference in its entirety.
Number | Date | Country | |
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62212295 | Aug 2015 | US |