US20240245233A1

US20240245233A1 - System and method for optimized shelf product shipping, storage, and display onsite

Info

Publication number: US20240245233A1
Application number: US18/421,563
Authority: US
Inventors: Jacob H. Whitta
Original assignee: Creative Plastic Concepts LLC
Current assignee: Creative Plastic Concepts LLC
Priority date: 2023-01-24
Filing date: 2024-01-24
Publication date: 2024-07-25

Abstract

A system and method are provided for optimized shelf product shipping, storage, and display utilizing a pallet and one or more unassembled shelf assemblies designed for compact arrangement on the pallet. The system includes a standard size pallet and a plurality of unassembled shelf assemblies. Multiple unassembled shelf assemblies comprising shelf bodies and shelf components are stacked vertically and arranged in a compact configuration fully within a perimeter of the pallet and without overhang. The shelf components are housed in cavities formed between adjacent shelf bodies. Accordingly, the unassembled shelf assemblies consolidate into high-density vertical stacks with minimal wasted space and without loose parts. This enables efficient transportation while reducing risks including loss of or damage to the shelf bodies and shelf components. The system provides efficient, cost-effective, and safe shipping, storage, and display of unassembled shelf assemblies by maximizing the number of unassembled shelf assemblies fit on the pallet.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

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.

FIELD

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.

INTRODUCTION

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.

SUMMARY

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.

DRAWINGS

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.

FIG. 1 is a top perspective view of a system for optimized shelf product shipping, storage, and display;

FIG. 2 is a top perspective view of a system for optimized shelf product shipping, storage, and display, featuring a partially exploded view of an unassembled shelf assembly

FIG. 3 top plan view thereof;

FIG. 4 is a front elevational view thereof;

FIG. 5 is a right-side elevational view thereof;

FIG. 6 is a top plan view of a pallet;

FIG. 7 is a top plan view of a single shelf body;

FIG. 8 is a bottom plan view thereof;

FIG. 9 is a right-side elevational view thereof;

FIG. 10 is a top perspective view thereof;

FIG. 11 is a left-side elevational view thereof;

FIG. 12 is a front elevational view of a shelf assembly in an assembled configuration formed of poles, shelf bodies, and foot adjusters;

FIG. 13 is a side elevational view thereof;

FIG. 14 is a top plan view thereof;

FIG. 15 is a top perspective view thereof; and

FIG. 16 is a flow diagram depicting a method for optimized shelf product shipping, storage, and display.

DETAILED DESCRIPTION

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 FIGS. 1-16 .
With reference to FIGS. 1, 2, and 6 , the system 100 can include a pallet 102 and at least one unassembled shelf assembly 104. The pallet 102 can have a perimeter 106. The unassembled shelf assembly 104 can be disposed on the pallet 102 in an unassembled configuration 108. The unassembled shelf assembly 104 can include one or more shelf bodies 110 and one or more shelf components 112 configured to connect to one another to form a shelf product 114 in an assembled configuration 116, as shown in FIGS. 12-15 . The unassembled shelf assembly 104 can be fully contained on the pallet 102 and not extend beyond the perimeter 106 of the pallet 102 when placed thereon.
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 FIG. 1 , the pallet 102 can have a pallet height 122. As a non-limiting example, the pallet height 122 can be between about 3 inches and about 7 inches. In another embodiment, the pallet height 122 can be between about 4 inches and about 6 inches. In a more particular embodiment, the pallet height 122 can be about 5 inches. Advantageously, this range of heights can provide adequate support depending on the material from which the unassembled shelf assembly 104 is fabricated from. The pallet height 122 can be selected to provide additional support for the unassembled shelf assembly 104 and to facilitate the handling of the pallet 102 during shipping, storage, and display. One of ordinary skill can select any suitable pallet height 122 for the pallet 102, within the scope of the present disclosure.
As shown in FIGS. 7, 8, 10, and 14 , the shelf bodies 110 can be substantially rectangular and have a shelf body width 124 and a shelf body length 126, according to certain embodiments. As a non-limiting example, the shelf body width 124 can be between about 18 inches and about 24 inches and, more particularly, can be about 20 inches. In another non-limiting example, the shelf body length 126 can be between about 20 inches and about 28 inches. In a yet another non-limiting example, the shelf body length 126 can be between about 22 inches and about 26 inches. In a further non-limiting example, the shelf body length 126 can be about 24 inches. One of ordinary skill in the art can select any suitable shelf body width 124 and shelf body length 126, as well as any suitable shape and configuration for the shelf bodies 110, within the scope of the present disclosure.
In certain embodiments, an opening 123, as shown in FIG. 5 , can be disposed between adjacent shelf bodies 110 of the unassembled shelf assembly 104 when in the unassembled configuration 108 and stacked on the pallet 102. In a non-limiting example, the opening 123 between each adjacent shelf body 110 can be less than about 5 millimeters. In another non-limiting example, the opening 123 between each adjacent shelf body 110 can be less than about 3 millimeters. In yet another non-limiting example, the opening 123 between each adjacent shelf body 110 can be less than about 1 millimeters. The openings 123 between adjacent shelf bodies 110 can be uniform or different. One of ordinary skill in the art can select any suitable opening between each adjacent shelf body 110, within the scope of the present disclosure. Advantageously, the opening 123 between each of the shelf bodies 110 when unassembled and vertically stacked on the pallet 102 is minimized to reduce wasted space. In certain embodiments, the opening 123 between the shelf bodies 110 is less than about 5 millimeters, which allows for a high-density packing of the shelf bodies 110 on the pallet 102. This configuration maximizes the number of shelf bodies 110 that can be transported on a standard pallet 102, thereby reducing shipping costs and the environmental impact of transportation.
As shown in FIG. 2 , the shelf components 112 of the unassembled shelf assembly 104 can be disposed in one or more cavities 128 formed between each pair of adjacent shelf bodies 110 of the unassembled shelf assembly 104. As such, the shelf components 112 can be fully enclosed between shelf bodies 110 when the unassembled shelf assembly 104 is in the unassembled configuration 108, thereby protecting the shelf components from loss and/or damage during loading, transport, storage, and display. The shelf components 112 can connect to the shelf bodies 110 and/or to one another to form the shelf product 114 in the assembled configuration 116, as shown in FIG. 15 . Additionally, the shelf components 112 can connect the shelf bodies 110 to one another to form the shelf product 114 in the assembled configuration 116 during use, according to various embodiments. Examples of shelf components 112 can include one or more poles 130, shelf end caps 132, foot adjusters 134, top caps 138, interlocking tees 140, and/or wall mount brackets 142.
With reference to FIGS. 12, 13 and 15 , one or more poles 130 can be disposed between a pair of adjacent shelf bodies 110 in the assembled configuration 116, according to certain embodiments. The poles 130 can be configured to couple a shelf body 110 to another shelf body 110 in the assembled configuration 116. Each pole 130 can also include a stiffener (not shown) configured to support the pole 130 in the assembled configuration 116. As an example, the stiffener can be an additive added during the formation of the pole 130 or a physical structure such as a rib. Advantageously, the stiffener can provide the pole 130 with additional structural support and strength, as well as militate against the pole 130 torquing due to weight placed on the shelf product 114 in the assembled configuration 116 and during use.
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 FIGS. 12, 13, and 15 , one or more foot adjusters 134 can be configured to removably connect to one or more shelf bodies 110 during use. In certain embodiments, the foot adjuster 134 can be disposed adjacent to a bottom shelf 136 of the shelf bodies 110 in the assembled configuration 116 and during use using any suitable connecting mechanism such as a friction fit or a threaded fit, as non-limiting examples. In certain embodiments, the unassembled shelf assembly 104 can include up to four (4) foot adjusters 134. Desirably, the foot adjusters 134 can allow for adjustment of the shelf bodies 110, and more specifically, the bottom shelf 136 of the shelf bodies 110, relative to any surface on which they are disposed when in the assembled configuration 116. The foot adjuster 134 allows for the location and height of the shelf bodies 110 to be adjusted when in the assembled configuration 116, providing stability and adaptability on uneven surfaces.
With reference to FIG. 15 , one or more top caps 138 can be disposed on an end of one of more of the poles 130, according to certain embodiments. The top caps 138 can also be used to cover an aperture on a shelf body 100, such as an aperture configured to receive a pole 130. Advantageously, the top cap 138 can militate against items falling into the pole 130 when the shelf product 114 is in the assembled configuration 116.
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 FIGS. 1-5 , a plurality of unassembled shelf assemblies 104 can be disposed on the pallet 102. In certain embodiments, the plurality of unassembled shelf assemblies 104 can be disposed on the pallet 102 in a two-by-two configuration. The pallet 102 can be divided into one or more pallet sections 144, as shown in FIG. 6 . In certain embodiments, the pallet can be divided into four equal pallet sections 144, and each pallet section 144 can include at least one unassembled shelf assembly 104, as shown in FIGS. 1-5 . Each unassembled shelf assembly 104 can have an assembly width 146 and an assembly length 148 that is the same as or less than a pallet section width 150 and a pallet section length 152, respectively, on which it is disposed. Advantageously, this can allow for the unassembled shelf assemblies 104 to be fully contained on the pallet 102 without wasting unused space. In certain embodiments, each pallet section 144 of the pallet 102 can have a pallet section width 150 of about 20 inches and a pallet section length 152 of about 24 inches, and each unassembled shelf assembly 104 can have an assembly width 146 of about 20 inches and an assembly length 148 of about 24 inches.
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 FIGS. 1-4 , the plurality of unassembled shelf assemblies 104 can include about sixteen unassembled shelf assemblies 104. For example, four groups of unassembled shelf assemblies 104, each group including four unassembled shelf assemblies 104 vertically stacked on top of one another, can be disposed on the pallet 102. More specifically, each group of four unassembled shelf assemblies 104 vertically stacked on top of one another can be disposed on a corresponding pallet section 144 of the pallet 102, giving a total of sixteen unassembled shelf assemblies 104 on the pallet 102. Advantageously, use all of the surface area of a top surface 154 of the pallet 102 without the unassembled shelf assemblies 104 extending beyond the perimeter 106 of the pallet 102 can be achieved. It should be appreciated that any number of unassembled shelf assemblies 104 stacked in any suitable configuration and having any desired dimensions can be arranged on the pallet 102, as determined by one of skill in the art.
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 FIGS. 1 and 2 . It should be appreciated that any number of shelf bodies 110 having any desired dimensions alone or in combination with any desirable shelf components 112 can be arranged in any suitable configuration to form the unassembled shelf assembly 104, as determined by a skilled artisan.
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 FIGS. 1-4 . This configuration militates against damage during transport and complies with shipping regulations that require items to be contained within pallet 102 boundaries. Additionally, the surface area of the top surface 154 of the pallet is maximized with little to no wasted space. The pallet 102 can be designed to be compatible with standard pallet sizes, which are commonly used in the industry for ease of handling and compatibility with shipping and storage.
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 FIG. 16 , an embodiment of a method 200 for optimized shipping, storage, and display of unassembled shelf assemblies 104 is shown. The method 200 can include a first step 202 of providing the system 100, including the pallet 102 and one or more unassembled shelf assemblies 104. In a step 204, the pallet 102 can be divided into a predetermined number of pallet sections 144. The pallet 102 can be divided into four equal pallet sections 144, for example. The step 204 of dividing the pallet 102 into a desired number of pallet sections 144 can include marking one or more surfaces of the pallet 102, such as the top surface 154. One or more indicators (not shown), such as a visual indicator, can be used to delineate the boundaries of each pallet section 144. In a step 206, a desired number of unassembled shelf assemblies 104 can be positioned one on top of another to form one or more vertical stacks 156 of unassembled shelf assemblies 104. For example, four vertical stacks 156 of unassembled shelf assemblies 104 can be formed, each vertical stack 156 including four unassembled shelf assemblies 104 positioned one on top of another, giving a total of sixteen unassembled shelf assemblies 104. It should be appreciated that any suitable number of vertical stacks 156 having any desired number of unassembled shelf assemblies 104 can be formed, as determined by one of skill in the art. In a step 208, each vertical stack 156 of unassembled shelf assemblies 104 can be positioned on a corresponding pallet section 144. A step 210 can include arranging each vertical stack 156 such that each vertical stack 156 can be fully contained within its respective pallet section 144 without any overhang over the perimeter 106 of the pallet 102. More specifically, step 210 of the method 200 can include optimizing the volume occupied by the vertical stacks 156 on the top surface 154 of the pallet 102 by aligning the edges of each vertical stack 156 of unassembled shelf assemblies 104 with the edges of the corresponding pallet section 144 to maximize use of the surface area of the top surface 154 of the pallet 102.
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

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.

Claims

What is claimed is:

1. A system for shelf product shipping, storage, and display comprising:

a pallet having a perimeter; and

an unassembled shelf assembly disposed on the pallet, the unassembled shelf assembly including a plurality of shelf bodies,

wherein the unassembled shelf assembly is fully contained on the pallet and does not extend beyond the perimeter of the pallet.

2. The system for shelf product shipping, storage, and display of claim 1, wherein the pallet is a standard pallet size as determined by at least one of the Grocery Manufacturers Association (GMA) and the International Organization for Standardization (ISO).

3. The system for shelf product shipping, storage, and display of claim 1, wherein the perimeter includes a pallet length of 40 inches, and a pallet width of 48 inches.

4. The system for shelf product shipping, storage, and display of claim 3, wherein the unassembled shelf assembly has an assembly width and an assembly length that does not exceed the pallet width and the pallet length of the pallet.

5. The system for shelf product shipping, storage, and display of claim 1, wherein the unassembled shelf assembly includes shelf components including one or more of a pole, a foot adjuster, a top cap, an interlocking tee, and a shelf end cap.

6. The system for shelf product shipping, storage, and display of claim 5, wherein the shelf components are disposed between one or more pairs of adjacent shelf bodies.

7. The system for shelf product shipping, storage, and display of claim 1, wherein at least one shelf body of the plurality of shelf bodies and at least one shelf component is injection molded and formed using a single piece of material.

8. The system for shelf product shipping, storage, and display of claim 1, wherein an opening between adjacent shelf bodies of the plurality of shelf bodies is less than 1 millimeter.

9. The system for shelf product shipping, storage, and display of claim 1, wherein a plurality of unassembled shelf assemblies is disposed on the pallet.

10. A system for shelf product shipping, storage, and display comprising:

a pallet having a perimeter; and

a plurality of unassembled shelf assemblies disposed on the pallet, each unassembled shelf assembly of the plurality of unassembled shelf assemblies including a plurality of shelf bodies and a plurality of shelf components,

wherein each unassembled shelf assembly of the plurality of unassembled shelf assemblies is fully contained on the pallet and does not extend beyond the perimeter of the pallet.

11. The system for shelf product shipping, storage, and display of claim 10, wherein the plurality of unassembled shelf assemblies is sixteen unassembled shelf assemblies.

12. The system for shelf product shipping, storage, and display of claim 11, wherein the plurality of unassembled shelf assemblies is configured as four vertical stacks and each vertical stack includes four unassembled shelf assemblies.

13. The system for shelf product shipping, storage, and display of claim 12, wherein the pallet is divided into four equal pallet sections.

14. The system for shelf product shipping, storage, and display of claim 13, wherein a pallet width of each pallet section is equal to an assembly width of each unassembled shelf assembly and a pallet length of each pallet section is equal to an assembly length of each unassembled shelf assembly.

15. The system for shelf product shipping, storage, and display of claim 13, wherein a visual indicator delineates the four equal pallet sections.

16. The system for shelf product shipping, storage, and display of claim 10, wherein the plurality of shelf components is disposed in one or more cavities formed between one or more pairs of adjacent shelf bodies of the plurality of shelf bodies.

17. The system for shelf product shipping, storage, and display of claim 10, wherein at least one shelf body of the plurality of shelf bodies and at least one shelf component of the plurality of shelf components is injection molded and formed using a single piece of material.

18. The system for shelf product shipping, storage, and display of claim 10, wherein an opening between a pair of adjacent shelf bodies of the plurality of shelf bodies is less than 1 millimeter.

19. A method for optimized shelf product shipping, storage, and display, comprising the steps of:

providing a pallet having a perimeter;

providing a plurality of unassembled shelf assemblies disposed on the pallet, the unassembled shelf assemblies fully contained on the pallet and not extending beyond the perimeter of the pallet and including a plurality of shelf bodies and a plurality of shelf components;

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.

20. The method for optimized shelf product shipping, storage, and display of claim 19, wherein the plurality of unassembled shelf assemblies includes sixteen unassembled shelf assemblies configured as four vertical stacks.