The present technology relates to systems, articles, and methods for optimizing shipping and storage, and, more particularly, shelf product shipping and storage using standard pallet assemblies.
This section provides background information related to the present disclosure which is not necessarily prior art.
Goods are shipped all around the world daily to provide consumers with products in a quick and efficient manner. Typically, in the routine shipment of goods, a multitude of products of the same type are assembled together so that they can be shipped efficiently. This can be achieved by using pallets. Pallets include flat structures onto which the products are stacked and can be loaded using a lift truck or forklift. Commonly, due to the nature of goods being varying shapes and sizes, there is wasted space on the pallet that results in less efficient packing and shipping. Utilizing the entire area of the pallet, without goods extending beyond the perimeter of the pallet, allows for efficient shipment, storage, and display of goods.
The shipping, storage, and display of shelfing products in particular has long presented challenges in organization and efficient packaging and shipping. Typically, shelving products are shipped in bulk on large pallets that are lifted and moved by heavy machinery. Bulk packaging and stacking of traditional shelving products on standard pallets, however, is often inefficient due to wasted space and unsafe due to unstable configurations.
Various attempts have been made to enhance efficiency in transporting unassembled shelving products. However, shelving units often have numerous pieces and parts that make efficient, safe stacking difficult to accomplish. Additionally, the dimensions of the shelving products and/or the accompanying pieces and parts typically results in wasted space on a standard pallet, overhang, or both. Shelving products may therefore arrive at their destination damaged or broken due to shifting during transport and/or impact from items directly adjacent the pallet and/or shelving products.
Additionally, known shelving products are inefficient with respect to storage prior to and upon arrival at a desired destination. More efficiently arranged modular shelving products are desired in order to optimize storage and/or retail floor space and provide a more organized, useful, and attractive display for businesses and/or customers. Additionally, eliminating pallet overhang also militates against damage.
Accordingly, there is a continuing need for optimized shelving product shipping and storage systems and methods that maximize efficient and organized stacking and storage on standard pallets, and that protect the shelving product from damage during transport and storage. Ideally, a plurality of unassembled shelving products should be arranged in a safe and stable configuration on a standard pallet.
In concordance with the instant disclosure, optimized shelving product shipping and storage systems and methods that maximize efficient and organized stacking and storage on standard pallets, protect the shelving product from damage during transport and storage, and that arrange the shelving product in a safe and stable configuration, have surprisingly been discovered.
The present technology includes articles of manufacture, systems, and processes that relate to optimized shipping, storage, and display of shelf products utilizing stackable unassembled shelf assemblies and standard pallets.
In certain embodiments, a system for shelf product shipping, storage, and display can include a pallet having a perimeter and one or more unassembled shelf assemblies disposed on the pallet, where each of the one or more unassembled shelf assemblies can include multiple shelf bodies that are fully contained on the pallet without extending beyond the perimeter of the pallet.
In certain embodiments, a system for shelf product shipping, storage, and display can include a pallet having a perimeter and a plurality of unassembled shelf assemblies disposed on the pallet. Each of the unassembled shelf assemblies can include a plurality of shelf bodies and a plurality of shelf components, and the unassembled shelf assemblies can be fully contained on the pallet without extending beyond the perimeter of the pallet. The plurality of unassembled shelf assemblies can include sixteen unassembled shelf assemblies configured as four vertical stacks. Each vertical stack can include four unassembled shelf assemblies. The pallet can be divided into four equal pallet sections, a pallet width of each pallet section can be equal to an assembly width of each unassembled shelf assembly, and a pallet length of each pallet section can be equal to an assembly length of each unassembled shelf assembly.
In certain embodiments, a method for optimized shelf product shipping, storage, and display can include providing a pallet having a perimeter and providing a plurality of unassembled shelf assemblies disposed on the pallet. The unassembled shelf assemblies can be fully contained on the pallet without extending beyond the perimeter of the pallet. Each of the unassembled shelf assemblies can include a plurality of shelf bodies and a plurality of shelf components. Additional steps can include dividing the pallet into a predetermined number of pallet sections, vertically stacking a predetermined number of unassembled shelf assemblies on top of one another to form one or more vertical stacks, positioning each vertical stack on a corresponding pallet section, and arranging each vertical stack such that each vertical stack is fully contained within the corresponding pallet section.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments, including where certain steps can be simultaneously performed, unless expressly stated otherwise. “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “substantially” in describing the broadest scope of the technology. “About” when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” and/or “substantially” is not otherwise understood in the art with this ordinary meaning, then “about” and/or “substantially” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters.
Although the open-ended term “comprising,” as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments may alternatively be described using more limiting terms such as “consisting of” or “consisting essentially of.” Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or process steps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that may be recited in the art, even though element D is not explicitly described as being excluded herein.
As referred to herein, disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of “from A to B” or “from about A to about B” is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter may define endpoints for a range of values that may be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, and so on.
When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
The present disclosure relates to a system and method for optimized unassembled shelf product shipping, storage, and display. The system is designed to maximize space utilization during the transport, storage, and display of unassembled shelf assembly products using standard pallets and to facilitate safe, organized, and efficient transport, storage, and display of the unassembled shelf assembly products. More specifically, the present technology relates to a system 100 for shipping, storing, and displaying unassembled shelf assembly products and a method 200 thereof, for example, as shown generally in
With reference to
The pallet 102 can be substantially rectangular. The pallet 102 can be a standard pallet size as determined by Grocery Manufacturers Association (GMA) and the International Organization for Standardization (ISO). The pallet 102 can have a pallet width 118 and a pallet length 120. As a non-limiting example, the pallet width 118 can have a length of about 40 inches and the pallet length 120 can have a length of about 48 inches. Advantageously, these dimensions are consistent with standard pallet dimension requirements as set out by the GMA and ISO. Accordingly, a pallet 102 with these standard dimensions can allow for the system 100 to be used in a variety of applications with a large assortment of products. One of ordinary skill in the art can select any suitable lengths for the pallet width 118 and the pallet length 120, within the scope of the present disclosure.
As shown in
As shown in
In certain embodiments, an opening 123, as shown in
As shown in
With reference to
One or more shelf end caps 132 can be coupled to an edge of one or more shelf bodies 110. Shelf end caps 132 can be coupled to opposite edges of a shelf body 110. Advantageously, the end caps can provide the shelf body 110 with a clean edge surface to militate against objects becoming trapped within one or more shelf bodies 110.
With renewed reference to
With reference to
One or more interlocking tees 140 can be can allow for the shelf product 114 in the assembled configuration 116 to be coupled to another shelf product 114 in the assembled configuration 116 to create a larger storage area with increased structural support and stability. Additionally, one or more wall mount brackets 142 can allow for a user to mount the shelf product 114 to a wall when in the assembled configuration 116 and militate against falling over when assembled and in use.
It should be appreciated that any suitable shelf components 112 can be included in one or more cavities 128 formed between each pair of adjacent shelf bodies 110 of the unassembled shelf assembly 104, as determined by one of skill in the art. Advantageously, the unassembled shelf assembly 104 can include all of the shelf components 112 and shelf bodies 110 needed for assembly of the shelf product 114. The shelf components 112 and shelf bodies 110 are efficiently packaged to take up minimal space during transport, storage, and display of the unassembled shelf assembly 104. Additionally, packaging of the shelf components 112 in the one or more of the cavities 128 militates against shelf components 112 becoming lost, stolen, or damaged during transport, storage, and display of the unassembled shelf assembly 104. Likewise, it is easy for a consumer to safely transport the unassembled shelf assembly 104 after purchase because the shelf components 112 are safely contained in one or more of the cavities 128. For example, the shelf bodies 110, cavities 128 formed therein and therebetween, and shelf components 112 contained in the cavities 128 can be packaged, wrapped, tied, taped, and the like to provide for a self-contained and easily transportable unassembled shelf assembly 104 that minimizes separation and loss of shelf components 112.
With reference to
In certain embodiments, the plurality of unassembled shelf assemblies 104 can include about eight unassembled shelf assemblies 104. A set of two unassembled shelf assemblies 104 vertically stacked on top of one another can be placed in each pallet section 144 of the pallet 102 for a total of eight unassembled shelf assemblies 104. In another non-limiting example, the plurality of unassembled shelf assemblies 104 can include about twelve unassembled shelf assemblies 104. A group of three unassembled shelf assemblies 104 stacked vertically on top of one another can be placed in each pallet section 144 of the pallet 102 for a total of twelve unassembled shelf assemblies 104.
In certain embodiments, with renewed reference to
In certain more particular embodiments, each unassembled shelf assembly 104 can include five shelf bodies 110 and one or more shelf components 112, as shown in
In certain embodiments, one or more of the shelf bodies 110 and/or the shelf components 112 of the unassembled shelf assembly 104 can be injection molded. One or more of the shelf bodies 110 and/or the shelf components 112 can be formed of one continuous body using the same material. For example, one or more of the shelf bodies 110 and one or more shelf components 112 can be injection molded and formed by a single piece of plastic or metal. The shelf bodies 110 and the shelf components 112 of the unassembled shelf assembly 104 can be coupled together in this manner without using fasteners before and during transport, storage, and display. This can simplify the manufacturing process and can minimizes the need for assembling separate components. Additionally, this militates against damage to or loss of the shelf bodies 110 and/or shelf components 112 during shipping, storage, and display.
The unassembled shelf assembly 104 can be fabricated using any suitable solid, durable material. As non-limiting examples, the unassembled shelf assembly 104 can be formed from various polyolefins and mixtures thereof, including polypropylene, high density polyethylene (HDPE), and/or polyethylene terephthalate (PET). One of ordinary skill in the art can select other suitable materials for forming the unassembled shelf assembly 104 within the scope of the present disclosure. These materials provide stability and durability to the unassembled shelf assembly 104 as it is transported, stored, and used. The choice of material can be based on the requirements for strength, durability, and cost-effectiveness, as non-limiting examples.
Additionally, the unassembled shelf assembly 104 is designed to be fully contained on the pallet 102 without extending beyond the perimeter 106 of the pallet 102, as shown in
The dimensions of the unassembled shelf assembly 104 are selected to optimize the use of space on the pallet 102 while allowing for efficient shipping, storage and display. In certain embodiments, the unassembled shelf assemblies 104 and the pallet 102 can be substantially rectangular in shape. This substantially rectangular shape contributes to the efficient use of space and stability of the system 100 and is advantageous for stacking and arranging multiple pallets 102 in shipping containers, trucks, or storage areas.
With reference now to
In certain embodiments, the method 200 can include additional steps. In one non-limiting example, a step of measuring the dimensions of each unassembled shelf assembly 104 to ensure that the dimensions of each unassembled shelf assembly 104 do not exceed the dimensions of their corresponding pallet section 144 can be included. In another non-limiting example, a step of adjusting the positions of each shelf body 110 and/or each unassembled shelf assembly 104 within each vertical stack 156 to ensure proper alignment, even distribution of weight, and stability of each vertical stack 156 can be included. A step of securing the vertical stacks 156 to the pallet 102 using any suitable securing mechanism to prevent movement during transport while maintaining the containment of each vertical stack 156 within its respective pallet section 144 can be included, according to certain embodiments. In certain embodiments, a step of optimizing the volume occupied by the vertical stacks 156 can include selecting a certain number and configuration of unassembled shelf assemblies 104 of identical or varying sizes to create a tight fit within each pallet section 144, thereby minimizing wasted space and maximizing the number of unassembled shelf assemblies 104 per pallet 102.
In certain embodiments, a step of utilizing interlocking features (not shown) to connect and further stabilize each unassembled shelf assembly 104 within each vertical stack 156 and/or vertical stacks 156 adjacent to one another can be included in the method 200. In certain embodiments, a step of utilizing the interlocking tees 140 to maintain the integrity of each unassembled shelf assembly 104 individually and/or with respect to adjacent unassembled shelf assemblies 104 disposed on adjacent pallet sections 144 can be included to maximize stability during handling and transport.
In certain embodiments, the method 200 can include a step of applying protective material between and/or around one or more unassembled shelf assemblies 104 to prevent damage during transport. Arranging the vertical stacks 156 can include a step of leaving a space between adjacent vertical stacks 156 to allow for expansion and contraction due to temperature changes during transport, while still preventing overhang over the perimeter 106 of the pallet 102.
In certain embodiments, the method 200 can include arranging the unassembled shelf assemblies 104 on the pallet 102 in a two-by-two configuration. Advantageously, this arrangement allows for the unassembled shelf assemblies 104 to be fully contained on the pallet 102 without overhang and without wasting pallet space, providing an efficient and stable means for shipping, storing, and displaying the unassembled shelf assemblies 104. One or more steps included in the method 400 can be repeated, omitted, or performed in any desirable alternative order, as needed.
In certain embodiments, a vertical stack 156 can be formed after positioning a first unassembled shelf assembly 104 on a pallet section 144 of the pallet 102, thereby allowing the vertical stack 156 to be formed on the pallet 102, rather than forming the vertical stack 156 and then moving the vertical stack 156 onto the pallet 102. Vertical stacks 156 can be formed in unison after positioning an unassembled shelf assembly 104 on each pallet section 144 of the pallet 102. More specifically, forming the vertical stacks 156 can be coordinated such that the building of each layer of adjacent unassembled shelf assemblies 104 is completed before moving on to the next layer of adjacent unassembled shelf assemblies 104. It should be appreciated that any suitable steps necessary for setting up, securing, transporting, storing, and displaying the system 100 including the pallet 102 and the unassembled shelf assemblies 104 can be included in the method 200 in any desired order, as determined by someone skilled in the art.
The system and method disclosed herein provide significant advantages over known shipping, storage, and display systems and methods for unassembled shelf assemblies 104. The system and method of the present disclosure provide an efficient and stable means for shipping, storing, and displaying unassembled shelf assemblies 104. Additionally, the system and method provide a cost-effective way to ship, store, and display unassembled shelf assemblies 104, as the unassembled shelf assemblies 104 can be arranged in a compact and efficient manner on the pallet 102. By reducing the amount of wasted space on the top surface 154 of the pallet 102, the system and method allow for more unassembled shelf assemblies 104 to be shipped and stored on a standard pallet 102. Additionally, damage to the unassembled shelf assemblies is reduced due to no overhang. Packaging of shelf components 112 in the cavities 128 of the unassembled shelf assemblies 104 militates against lost and/or damaged parts. Collectively, these features lead to cost savings in shipping and storage, as well as a reduction of the environmental impact of transportation.
Example embodiments of the present technology are provided with reference to the several figures enclosed herewith.
In one particular example, the disclosed system and method revolutionize the unassembled shelf assembly shipping, storing, and displaying process by optimizing the number of uniform unassembled shelf assemblies that can be transported and stored per pallet. The system and method are specifically tailored to ensure that the unassembled shelf assemblies are arranged to maximize pallet space without any overhang. This is achieved by adhering to the dimensions of standardized pallets, which are widely accepted in the industry, thereby facilitating seamless integration into the existing logistical framework of shipping, warehouse, and retail operations. This is further achieved by including the shelf components in one or more cavities between the shelf bodies of the unassembled shelf assemblies.
The optimization process begins by dividing the pallet into four equal pallet sections, each pallet section designated to hold a vertical stack of unassembled shelf assemblies. The uniformity in size and weight of the unassembled shelf assemblies allows for a highly efficient stacking process, where each unit fits snugly within the allocated pallet section. This precise arrangement ensures that all vertical stacks are fully contained within the pallet's perimeter, making the most of the available surface area on the top surface of the pallet and significantly increasing the number of unassembled shelf assemblies that can be shipped on a single pallet. Additionally, the precise arrangement ensures that there is no overhang of the unassembled shelf assemblies, thereby militating against damage to the unassembled shelf assemblies and any adjacent items, as well as optimizing safety for those handling the pallets and the unassembled shelf assemblies.
The system and method can include the strategic placement of interlocking features, such as interlocking tees, disposed on the unassembled shelf assemblies, which can maintain the stability of each vertical stack both internally and in combination with adjacent vertical stacks during transportation and handling. This is particularly important for large retail outlets and warehouses where the movement of the pallets is frequent and requires the unassembled shelf assemblies to remain secure on the pallet.
The system and method represent a substantial improvement for shipping, storage, and display of unassembled shelf assemblies prior to sale of the unassembled shelf assemblies by maximizing the shipping volume, streamlining the storage process, and preventing damage to and loss of the unassembled shelf assembly products. The uniformity and precision in the arrangement of the unassembled shelf assemblies relative to the pallet facilitates easy and efficient storing, shipping, display, and inventory management.
Overall, the disclosed system and methods emphasize the importance of space optimization, stability, and product and user safety in the transportation, storage, and display of unassembled shelf assemblies. By leveraging the standardization of pallet sizes and the uniformity of the unassembled shelf assemblies, the system and method provide cost-effective, environmentally friendly, and practical solutions. The ability to ship and store more unassembled shelf assemblies per pallet translates to direct cost savings and a more streamlined supply chain, ultimately benefiting retailers, customers, and the environment.
Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods can be made within the scope of the present technology, with substantially similar results.
This application claims the benefit of U.S. Provisional Application No. 63/481,219, filed on Jan. 24, 2023. The entire disclosure of the above application is incorporated herein by reference.
Number | Date | Country | |
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63481219 | Jan 2023 | US |