WO2011043674A1

WO2011043674A1 - System, method and apparatus for distribution of product

Info

Publication number: WO2011043674A1
Application number: PCT/NZ2010/000196
Authority: WO
Inventors: Roger Keith Palmer
Original assignee: Foodcap International Limited
Priority date: 2009-10-06
Filing date: 2010-10-06
Publication date: 2011-04-14

Abstract

Product distribution apparatus comprises a container (20) and shelf assembly (1). The container (20) is adapted to accommodate the shelf assembly (1) which includes a plurality of vertically spaced and laterally moveable shelves (5). The shelf assembly (1) is vertically moveable relative to the container (20) such that it may be raised and lowered to provide access to each of the shelves (5).

Description

SYSTEM, METHOD AND APPARATUS FOR DISTRIBUTION OF PRODUCT

Field of Invention The invention relates to systems, methods and apparatus for product distribution and storage. More particularly, the invention relates to retail distribution and has application to foodstuffs.

Background to the Invention Existing methods for delivery of products from a central warehouse or processing facility to retail shelves include a number of inefficiencies.

Stacking products on shelves, particularly in a retail environment, is a labour intensive exercise. Typically, articles to be stacked on retail shelves are provided from a storage facility in boxes on pallets. The articles are usually unpacked from individual boxes and manually lifted onto a container, trolley or shopping cart and sorted (again manually) into the appropriate shelving space. Therefore, products that are required at any particular point on the shelf must be located from a jumble of articles in the cart or trolley. With perishable products, such as meat, the time taken to perform the retail distribution process is important to product quality. The longer the meat is exposed to ambient temperatures, the lower its quality and the shorter its shelf life.

Product often requires a substantial amount of structural packaging during the distribution process. Excess packaging is wasteful in terms of time to take product out of packaging. It is also wasteful from an environmental perspective, and from a cost perspective in view of the required packaging materials.

There is often a substantial amount of manual lifting required to lift objects from boxes onto a cart or trolley, and then from the cart or trolley onto retail shelves, which may be up to a metre higher than the position of the product in the cart. This manual lifting of articles to be stacked may occur many times throughout a shelf stacking process, for example products needing to be lifted from a delivery vehicle such as a truck, for example, onto a pallet and then being lifted again from the pallet into the shelves. Manual lifting such as that described above means that only certain staff can be employed in view of the physical nature of the task. Furthermore, manual lifting also raises issues of work health and safety, particularly in relation to lifting issues such as back injuries for example. Retail workforce responsible for shelf stacking is often unmotivated. Inefficiencies and mistakes may occur as a result, for example incorrect placement of product in shelves and time wasted in repeated trips to the shop warehouse, which are undesirable to retailers.

In one system that has been previously proposed, a number of the disadvantages discussed above are overcome by using a shelving system as described in international patent publication WO2006/009482, the disclosure of which is incorporated herein by reference.

Object of the Invention It is an object of the invention to provide product distribution apparatus, methods and systems which increase the efficiency of product distribution or retail shelf stacking.

Alternatively, it is an object of the invention to provide product distribution apparatus or methods which will at least overcome one or more disadvantages of existing apparatus or methods.

Alternatively, it is an object of the invention to at least provide the public with a useful alternative to existing product distribution apparatus or methods.

Summary of the Invention

According to a first aspect of the invention, there is provided a product distribution apparatus comprising a container and shelf assembly, the container being adapted to accommodate the shelf assembly, the shelf assembly comprising a plurality of vertically spaced and laterally moveable shelves, and wherein the shelf assembly is vertically moveable relative to the container such that the shelf assembly may be raised and lowered to provide access to each of the shelves.

Preferably, adjacent shelves define a space therebetween, product(s) stored within the space being substantially supported and/or protected by the portions of the product distribution apparatus surrounding the space. Preferably, the product distribution apparatus is adapted to be used in a product distribution system wherein product is distributed to a distribution end facility, the product distribution apparatus, or at least one or more of the shelves thereof, being passed via a plurality of intermediary facilities and/or parties before arriving at the distribution end facility.

Preferably, the container has an open upper side or mouth. More preferably, access to a shelf is provided when the shelf is positioned above the open upper side or mouth of the container.

Preferably, the shelf assembly may be selectively and/or progressively moved to access particular products stored on the shelves.

Preferably, the shelves can be laterally moved to protrude out of the shelf assembly.

Preferably, the shelf assembly comprises shelf support members for supporting the plurality of shelves. More preferably, the shelves are adapted to laterally slide on the shelf support members.

Preferably, the shelves are adapted to be removed from the product distribution apparatus and used with or as retail shelves.

Preferably, product(s) stored in the container is/are visible when the shelf assembly is lowered. More preferably, the container is transparent and/or has a cage-like structure.

Preferably, product stored on a first shelf of the plurality of shelves is only accessible when the first shelf is raised above the open upper side of the container.

Preferably, the shelf assembly comprises side members upon which the shelf support members are mounted. More preferably, the spacing of the side members corresponds to the width of the shelves.

Preferably, the container comprises at least one guiding member on at least one inner side for guiding movement of the shelf assembly relative to the container.

Preferably, the shelf assembly comprises engagement means on an upper portion by which the self assembly can be raised and lowered relative to the container. Preferably, the container is adapted to be closed by a lid. More preferably, the lid is adapted to provide a substantially fluid tight seal.

Preferably, the side members are joined by brace members.

Preferably, the container is mounted on conveying means.

Preferably, the product distribution apparatus comprises a product identifying means. More preferably, the product identifying means is a barcode reader or an RFID reader device.

Preferably, the product distribution apparatus comprises memory means for storing product identification information read by the product identifying means.

Preferably, the product distribution apparatus comprises a display means and/or operator interface for displaying and/or editing the product identification information.

Preferably, the memory means is adapted to store information relating to the location of a product. More preferably, the location information comprises a location in the container. More preferably, the location information comprises a container shelf number.

Preferably, the shelf assembly is adapted to move to a height corresponding to the shelf number of an identified product. The product may be identified using the product identifying means.

Preferably, the product distribution apparatus is adapted to generate an inventory of products stored in the container.

Preferably, the product distribution apparatus is adapted to be positioned in functional relationship with a means for loading and/or a means for unloading. Preferably the means for loading and the means for unloading are adapted to load and unload product from the product distribution apparatus, respectively.

Preferably, the means for loading and/or the means for unloading comprise automated apparatus, for example an accumulator device. Preferably, the product distribution apparatus comprises a lifting mechanism for moving the shelf assembly relative to the container.

Preferably, the lifting mechanism is adapted to move the shelf assembly in response to a received signal. More preferably, the received signal is produced by a control device.

Preferably, the product distribution apparatus comprises a location detection device. More preferably, the lifting mechanism is adapted to move the shelf assembly based on a detected location of the product distribution apparatus.

According to a second aspect of the invention, there is provided a lifting device for lifting the shelf assembly of the product distribution apparatus according to the first aspect of the invention, the lifting device comprising:

receiving means for receiving the product distribution apparatus in relation to the lifting device; and

a lifting mechanism adapted to couple to the shelf assembly and controllably raise and lower the position of the shelf assembly relative to the container.

Preferably, the lifting mechanism is adapted to move to a plurality of preset positions. More preferably, the preset positions correspond to positions of shelves of the shelf assembly in relation to the open upper side of the container. In a preset position, a shelf is able to laterally slide outwards.

Preferably, the lifting device includes control means for controlling movement of the lifting mechanism.

Preferably, the receiving means comprises a frame of the lifting device.

Preferably, the lifting mechanism comprises:

a gantry;

a lifting arm adapted to be raised and lowered; and

an engagement mechanism for engaging with the shelf assembly.

Alternatively, the lifting mechanism comprises a gantry adapted to be raised and lowered. Alternatively, the lifting mechanism comprises an arm of fixed height adapted to carry a cable having an engagement mechanism for engaging with the shelf assembly, the cable being able to be shortened or lengthened using an actuator to raise and lower the shelf assembly. Preferably, an actuator is adapted to raise and lower the lifting arm. More preferably, the actuator may include any of the following, which are included here by way of example only: motor; hydraulic pump; or pneumatic system.

Preferably, the lifting device comprises a support means for supporting a protruding shelf of the product distribution apparatus at a particular height.

Preferably, the preset positions correspond to positions of shelves of the shelf assembly in relation to the support means. More preferably, in a preset position, a shelf is able to outwardly slide onto the support means.

Preferably, the lifting device comprises conveying means.

Preferably, the lifting device comprises a product identifying means. More preferably, the product identifying means is a barcode reader or a read/write RFID device.

Preferably, the lifting device comprises memory means for storing product identification information read by the product identifying means.

Preferably, the lifting device comprises a display means and/or operator interface for displaying and/or editing the product identification information.

Preferably, the lifting mechanism is adapted to move to a height corresponding to the shelf number of an identified product. The product may be identified using the product identifying means.

Preferably, the lifting device is adapted to generate an inventory of products stored in the container. Preferably, the lifting device comprises a location detection device. More preferably, the lifting mechanism is adapted to move the shelf assembly based on a detected location of the lifting device. ^

According to a third aspect of the invention, there is provided a method for distribution of products, the method comprising:

placing the products on a shelf;

moving the shelf into a shelf assembly adapted to comprise a plurality of vertically spaced shelves;

positioning the shelf assembly in a container adapted to accommodate the shelf assembly;

transporting the container to a destination; and

raising the shelf assembly controllably to at least one height suitable for removing products from the shelf.

The step of placing the products on the shelf can occur before or after the step of moving the shelf into the shelf assembly. Where, in this specification, steps of a process or method are discussed or defined in a particular order, it will be understood that the order is not limiting to the scope of the invention and the steps of the process or method may be performed in a different order if appropriate to the use of the invention.

Preferably, the method comprises receiving an order for products and placing products on the shelf based on the order.

Preferably, the method comprises retaining the products on the shelf and/or in the container from the step of placing the products on the shelf based on the order until removal of the products from the shelf by a distribution end party or at a distribution end facility. More preferably, the distribution end party is a retailer and/or the distribution end facility is a retail store. That is, the products are not removed from the shelf and/or the container at or by any intermediary parties or locations on the way from the location at which the products are ordered and initially placed on the shelf to the destination location, for example a retail store.

Preferably, the method comprises placing products in the container in an order corresponding to the order they will be removed from the container. Preferably, the method further comprises sliding the shelf laterally into and/or out of the shelf assembly. More preferably, the shelf is slid laterally out of the shelf assembly before removing products from the shelf. Preferably, the method comprises sliding the shelf laterally out onto a support means for supporting protruding shelves.

Preferably, the method comprises using the removed shelf with retail shelving. More preferably, the method comprises using the removed shelf as a retail shelf. The retail shelving may be in a customer-accessible part of a retail store or in a storage part of a retail store.

Preferably, the method comprises positioning the products on the shelf and/or moving the shelf into the shelf assembly at a height and lowering the shelf assembly into the container. Preferably, the method comprises placing a lid on the container.

Preferably, the method comprises modifying the atmosphere within the container.

Preferably, the shelf assembly is progressively or selectively moved to a plurality of heights suitable for removing products from the container. More preferably, the heights are suitable for removing shelves from the container.

Preferably, the method comprises providing control signals for controlling the height of the shelf assembly. The control signals may be provided by a user operated control device.

Preferably, the method comprises identifying products being placed on the shelf and/or in the container.

Preferably, identifying products comprises scanning the product using a product identifying means. More preferably, the product identifying means is a barcode reader or RFID reading device.

Preferably, the method comprises providing a shelf identifier at the time of identifying a product, the shelf identifier identifying which shelf in the container the product is placed on. Preferably, the method comprises providing identification information on the products stored in the container. More preferably, the identification information is provided on a display means. More preferably, the identification information is provided in a generated inventory. Preferably, the method comprises moving the shelf assembly to a height corresponding to the shelf height of an identified product.

Preferably, the method comprises receiving location information and moving the shelf assembly based on the received location information. More preferably, the location information comprises a location of the container in a retail store and the shelf assembly is moved to a height suitable for removal of a product from the container that is stored at or near the location.

According to a fourth aspect of the invention, there is provided a product distribution apparatus comprising a container and a shelf assembly, the container being adapted to accommodate the shelf assembly, the shelf assembly comprising a plurality of vertically spaced shelves, wherein the shelf assembly is vertically moveable relative to the container such that the shelf assembly may be raised and lowered to provide access to each of the shelves, and wherein adjacent shelves define a space therebetween, product stored within the space being substantially supported and/or protected by the portions of the product distribution apparatus surrounding the space.

According to a fifth aspect of the invention, there is provided a product distribution system comprising:

a shelf assembly comprising a plurality of shelves adapted to be positioned in the shelf assembly in a vertically spaced arrangement;

a container adapted to accommodate the shelf assembly, the container being transportable for distributing product stored in the container;

a loading facility for loading product to be distributed onto the shelves; and

transportation means for transporting the container from the loading facility to a distribution end facility,

wherein product is retained on the shelves and/or in the container from the loading facility to the distribution end facility.

Preferably, the shelf assembly is moveable relative to the container such that the shelf assembly may be raised and lowered to provide access to each of the shelves. Preferably, the product distribution system comprises intermediary distribution facilities, product being retained on the shelves and/or in the container at the intermediary distribution facilities.

Preferably, the loading facility and/or the distribution end facility comprise means for loading product from the shelves and means for unloading product from the shelves, respectively.

Further aspects of the invention, which should be considered in all its novel aspects, will become apparent to those skilled in the art upon reading of the following description which provides at least one example of a practical application of the invention.

Brief Description of the Drawings

One or more embodiments of the invention will be described below by way of example only, and without intending to be limiting, with reference to the following drawings, in which:

Figure 1 illustrates a part of a shelf assembly according to an embodiment of the

invention;

Figure 2 illustrates a part of a shelf assembly and container according to an embodiment of the invention;

Figure 3 illustrates a container according to an embodiment of the invention;

Figure 4 is a cross-sectional view of a product distribution apparatus according to an embodiment of the invention;

Figure 5 is a diagram of a lifting device according to an embodiment of the invention.

Brief Description of Preferred Embodiments of the Invention

Figure 1 illustrates part of a shelf or tray assembly 1 according to one embodiment of the invention. Assembly 1 comprises two side members 2 and 3 oriented substantially vertically and parallel but spaced apart from each other. Side members 2 and 3 are adapted to support a plurality of shelf or tray members which are each substantially horizontally disposed and are substantially stacked in a vertical arrangement one above another. The shelf members are and laterally moveable (i.e. moveable in the horizontal plane) to protrude outwards. Those skilled in the art will appreciate that the manner in which a plurality of shelf or tray members may be stacked vertically in a shelf assembly may be effected in a variety of ways. One such mechanism comprises side members 2 and 3 as described herein with reference to Figures 1 and 2. Other ways are also incorporated within the scope of the invention. Side members 2 and 3 have, on their inner sides, a plurality of shelf support members 4 positioned substantially horizontally and in alignment with corresponding supports on the inner side of the opposite panel. Shelf supports 4 are adapted to support shelf or tray members 5 between the side members 2 and 3. The shelves may be moved laterally out of the shelf assembly, for example the shelf supports may comprise runners in one embodiment wherein the shelves may laterally slide forwards and backwards on the runners. A shelf 5 is sized to fit between side members 2 and 3 and includes a projection 6 on each side adapted to rest on shelf supports 4 and slide therealong. Although the shelves are generally moveable laterally, it will be understood that the shelves or the members 2 or 3 or the shelf supports 4 may be constructed so that the shelves are maintained in a desired lateral position, for example disposed completely between members 2 and 3, or protruding from members 2 and 3 ready to accept product. In one embodiment this is achieved by requiring the shelves to move non-laterally movement in order to be moved outwards or inwards. For example, shelf supports may comprise a shelf locking mechanism for holding the shelves securely in place. The shelves may require an upward movement to be released from the locking mechanism before they can be moved laterally.

Shelf 5 is generally adapted to support a number of objects, such as retail products. Shelf 5 may be a substantially planar shelf or tray, or it may include side, front and/or back portions in the manner of a drawer. The type of shelf used may depend on the product stacked on the shelves. The spacing between the shelves when stacked in a spaced apart relationship may be chosen or selected according to the objects placed on the shelves. In one embodiment, the shelf supports 4 are closely spaced. This provides the ability to vary the number, height and position of shelves in the assembly according to requirements. In another embodiment, the position of the shelf supports may be changed as required. Preferably, the distance between shelf supports is less than the height of shelves typically used in the assembly where the shelves have side or front and/or back portions as shown in Figure 2. In other embodiments, shelves have no side, front or back portions. Figure 2 shows guiding members, in this case bars 7, that may in some embodiments be positioned on the inner side of a container within which the shelf assembly is positioned so as to project from inner wall surfaces of the containers, the bars abutting or being positioned near the outer sides of side members 2 and 3 to restrain movement of the side members and shelf assembly 1. The side members slide over bars 7 when in contact. In other embodiments, side members slide relative to the inner sides of container 20. In some embodiments the bars 7 are resilient so as to provide a biasing effect so that the shelf assembly is securely maintained in position within the container. In some embodiments, the frame of the shelf assembly such as side members 2 and 3 rely on the container for stability by abutting against the inner sides of the container. In other embodiments, the shelf assembly frame supports itself, for example by joining side members 2 and 3 by brace members, or interlocking, or mutually engaging formations within the container, or the like to maintain their spacing, in a manner as will be appreciated by those skilled in the art.

Figure 3 shows a container 20 which is adapted to receive the shelf assembly described with reference to Figures 1 and 2. Container 20 has a removable lid 22 which may be sealably attached to the mouth of the container to provide a substantially fluid tight seal so as to provide a desired environment within the container for products that may be disposed on tray members 4 within the container. This is advantageous for certain products including perishable foodstuffs such as meat products. The container preferably comprises some form of conveying means such as rollers or wheels 24. The container may also include a tamper evident feature to allow unauthorised access to the container to be detected. This may take a variety of forms, for example one or more seals about the lid. Container 20 preferably has substantially parallel sides.

Alternatively, or in addition the lid may simply be designed to be difficult to remove by unauthorised persons or equipment.

Container 20 may also have a rib 28 encircling the container approximately halfway between the lid and the wheels. Rib 28 extends out as far as the edges of lid 22, enabling container 20 to be pushed up against similar containers and connected together using appropriate means. The connected containers can be lifted with a forklift by insertion of the forklift prongs between the wheels of the containers. This "self palletizing" structure of the containers may enable a forklift to lift the containers from the front or the side. This is facilitated in a container embodiment in which each container only has four wheels; one at each corner.

In use, shelf assembly 1 is positioned inside container 20 with shelves arranged in a vertically spaced apart relationship as is shown diagrammatically in Figure 4. Product 30 is stored on the shelves as shown.

Shelf assembly 1 is vertically moveable with respect to container 20 when lid 22 is removed and container 20 has an open upper side. Shelf assembly 1 may be moved such that the shelves are progressively and/or selectively exposed above the height of container 20. A range of lifting mechanisms may be used, some of which will be described below. By raising and lowering shelf assembly 1 to a particular height, a particular shelf (and shelves above that shelf) is accessible for loading and removal of product, for example removing supermarket produce from a shelf and it on a supermarket shelf. Shelf assembly 1 may simply slide relative to the inner walls of container 1 or it may be mounted on runners located on the inner walls of container 1 , or otherwise.

In one embodiment, the shelf assembly is biased to be raised and lowered to a number of discrete positions. These positions may correspond with each shelf being positioned just above the level of container 20 for easy access. Those of skill in the art will appreciate that in some embodiments runners on the inside of container 20 are adapted such that shelf assembly 1 is biased to be raised and lowered to stop at certain positions. Alternatively, the lifting mechanisms such as those described below effect the bias at which heights the shelf assembly can be moved to.

In one embodiment, shelf assembly 1 has an engagement means on an upper portion by which the assembly can be raised and lowered. The engagements means may comprise a hook, handle or other components that a lifting means can couple to. In the embodiment illustrated in Figure 1 , side panels has a number of holes 8 near an upper edge which are used for lifting shelf assembly 1. By engaging a number of holes, the stress levels in the assembly during lifting are reduced.

When the shelf assembly is stacked with products of low mass, shelf assembly 1 may be raised and lowered by an operator manually lifting the assembly. However, typically the mass of product on the assembly will be too heavy for someone to manually lift. Figure 5 illustrates a lifting device 50 according to one embodiment of the invention. Some components of lifting device 50 are shown in exploded view. Lifting device 50 comprises an area 51 adapted to receive, or engage with, container 20. Area 51 is defined at least in part by frame 54. Lifting mechanism 52 comprises a gantry 53 and lifting arm 52. Arm 52 has a hook, loop or similar engagement mechanism provided at the distal end of the arm that engages with the engagement means on the upper side of shelf assembly 1 for the purposes of lifting. Arm 52 may be raised and lowered to lift or lower shelf assembly 1 out of, or into, container 20 respectively upon an actuator of the lifting device receiving a control signal. Movement of arm 52 may be effected manually by a pump device or automatically using a motor driven hydraulic pump, for example, or a pneumatic system. In one embodiment, two electrically operated synchronised linear actuators are used. These have an electric motor that turns a screw thread. The motor may be powered from a rechargeable battery.

In one alternative embodiment, gantry 53 may itself be able to be raised and lowered with respect to frame 54. In a further alternative embodiment, arm 52 may be of a fixed vertical height but instead carry a simple cable which has a hook to engage shelf assembly 1 with the cable being shortened or lengthened using a hand or motor operated winch provided on lifting device 50 or provided on container 20. In use, container 20 is moved into position in area 51 of lifting device 50 such that the sides of container 20 abut frame 54. Alternatively, the lifting device is moved into position about the container 20. Container 20 is preferably positioned such that the trays on shelf assembly 1 slide out in the direction of support means or shelf 55. Shelf 55 is positioned at a height above the level of the top of container 20 and comprises a horizontal surface adapted to support a tray as it is pulled out of shelf assembly 1. A tray can be left partially protruding from the shelf assembly and resting on shelf 55 while product is loaded or unloaded from the tray. A handle 56 may be attached to shelf 55 to provide a support for an operator to pull a heavily laden tray out of shelf assembly 1. Lifting device 50 may include a controller programmed to stop the movement of shelf assembly 1 at a number of preset positions, corresponding to the positions at which each tray or shelf can be slid out onto shelf 55. There may also be provided a manual control for moving the assembly.

Lifting device 50 also comprises conveying means such as wheels 57, the attachment of which to frame 54 is shown in exploded view in Figure 5. ln an alternative embodiment, the means for lifting shelf assembly 1 is comprised within container 20. For example, there may be a lifting mechanism positioned in the bottom of container 20 which engages with the bottom of shelf assembly 1 and pushes it up from below to raise the assembly or lowers to lower the assembly. This can be effected by, for example, hydraulic or pneumatic rams driven by a motor. A lifting mechanism provided within container 20 is advantageous in terms of space saving, but the cost of production of each container is substantially increased and the mechanisms are more likely to get damaged as the containers are frequently transported, which could be problematic. There will now be described methods by which container 20 and shelf assembly 1 are used for distribution of product. The description will refer to use in the example of a retail store supply chain. Other examples of product distribution are also envisaged and retail distribution is discussed herein for the purposes of example only. In one embodiment, an order for product is received, for example at a loading facility. As a result of receiving the order, product is loaded onto one or more shelves or trays and these are placed on shelf assembly 1 by sliding them onto shelf supports 4 at the required height. Shelf assembly 1 is raised and lowered into or out of container 20 so that the shelves can be inserted at a convenient height for a loading worker or a machine. For example, the shelves are loaded at the height of shelf 55 as shown in Figure 5. The shelves can be loaded onto shelf assembly 1 in any order, for example to maximise space. Preferably, shelves are progressively loaded in an order corresponding to later use, as will be described further below. In another embodiment, the shelves may be placed on the shelf assembly before product is loaded on the shelves. The loading facility is any location, building or apparatus at which product is loaded onto a container. This may occur at a variety of locations in the distribution process or supply chain. For example, this may occur at a product manufacturer or at a retail store warehouse. It is advantageous that product is loaded on to container 20 as early in the supply chain as possible since this negates the need for further loading and unloading of product onto different containers for transportation. In the case of milk, for example, the milk factory may load containers of milk directly onto shelves and load the shelves directly onto container 20 for distribution to supermarkets. This is a more efficient process than milk being delivered on, for example, a pallet to a supermarket distribution centre or warehouse, where it is then loaded onto container 20. However, the loading centre may include any location in the supply chain where product is loaded. Once container 20 is loaded with product a container lid may be put in place. Furthermore, if appropriate depending on the type of product transported, the atmosphere within container 20 can be modified if desired, for example by introduction of a preserving gas or gas at a particular pressure. This may be desirable for preserving the quality of some products such as meat. The container can then be transported on its own wheels 24 for example, or using other apparatus such as a pallet, forklift or truck, to transport the apparatus to a desired destination, such as a retail store.

Once the apparatus has been disposed in the retail store environment, which is the intended destination for the objects packed within the container (whether via another destination or not), then the lid of the container is removed and the lifting mechanism is used to begin lifting shelf assembly 1 from container 20. The lifting mechanism can be used to progressively or selectively lift the assembly for access to product on particular shelves of the shelf assembly, or the entire assembly can be substantially removed from the container before stacking begins. Product is unloaded from the shelf assembly onto the retail store shelves. The retail store shelves may be on the shop floor for access by customers, or in the store warehouse for later stacking on shop floor shelves. Preferably, the product is loaded directly onto the shelves on the shop floor since this reduces the number of times product needs to be loaded and unloaded and is therefore more efficient.

Preferably, product is loaded onto the shelves of the shelf assembly in a manner corresponding to the order the product is to be stacked in the retail store. For example, the product to be stacked first is placed on the uppermost shelf of shelf assembly 1 and the product to be stacked last is placed on the lowermost shelf. This enables the shelf assembly to be gradually lifted out of container 20 for unloading.

In one embodiment, the vertical spacing of the shelves and the housing of product placed thereon in the shelf assembly negates the need for structural packaging for the products.

Product stored in the space between adjacent shelves is substantially supported and/or protected by the portions of the product distribution apparatus surrounding the space, for example, the top of the shelf on which the product stands, the bottom of the shelf above, the inner sides of the side members and the inner sides of the front and back sides of the container. Where products are stacked from the shelf assembly straight onto retail shelves, or any other shelves, the shelf-stacking process is made more efficient by reducing the need to unpack product from packaging and reducing the amount of packaging that needs to be generally dealt with and disposed of. It is also envisaged that product can be placed on shelves suitable for use in the shelf assembly early in the supply chain or distribution process so that efficiencies such as those just described are enjoyed through the supply chain. In one embodiment, product manufacturers load product directly onto a shelf such as shelf 5, the product remaining on shelf 5 until it is loaded onto a retail shelf. Thus, the need for structural packaging for transportation / distribution purposes is greatly diminished, or is eradicated.

In a still further embodiment, shelf 5 is adapted to be used with or as retail shelving, such as those used in supermarkets. In this embodiment, when product needs to be placed in-store, shelf 5 is lifted from shelf assembly 1 and placed directly onto the in-store shelving structures. It may be swapped with the previous empty or part-empty shelf, which is placed onto assembly 1 for future use in the supply chain. Thus, product may be provided on a single shelf from manufacture to the end retailer, creating many handling and distribution efficiencies through the entire supply chain. Containers, shelf assemblies and shelves may be frequently passed from one facility or entity to another in the course of the supply chain. For example, a product manufacturer may load product onto a shelf and place in a container such as container 20 in the factory. This container is then passed to the distributor and later onto the end user, such as a retail store. It can be seen that where product is retained on a shelf and/or a shelf is retained in a container through the distribution process, significant efficiencies are created throughout the distribution process because less movement of individual products is required. In one embodiment, retail shelves may be effectively stacked in a loading facility, where the loading facility is an entirely different location to the retail store or distribution end facility, perhaps even as far back in the supply chain as the product manufacturer.

As mentioned, the distribution end facility may be a retail store. The containers may be used to provide product to a storage part of a retail store or to a customer-accessible part of a retail store, commonly termed the 'shop floor'. It will be understood that the terms loading facility and distribution end facility may refer to different facilities, locations or supply chain entities depending on the point of view of a user or party involved in the supply chain. All points of view and associated understanding of these terms are included herein. In a preferred embodiment, however, the loading facility receives an order for product and the distribution end facility stores or provides product to a customer or other end user. That is, the container preferably retains product from the start to the end of the supply chain to enhance distribution efficiencies. Intermediary facilities may also be included in the supply chain.

In one embodiment, product loaded on shelves within container 20 is visible even when the shelf assembly has not been raised. Container 20 may be made from a transparent casing, for example, or have a cage-like structure. This enables someone unloading product from container 20 to know which height the shelf assembly needs to be raised to for unloading.

The container may be adapted to be positioned in functional relationship with a means for loading and/or a means for unloading. The means for loading and means for unloading maybe any device, apparatus or user able to load and unload product from the container shelves, respectively. For example, an accumulator device, such as is known in the art, can be used in conjunction with a container according to the invention at any point in the supply chain, but particularly at the distribution end facility, of which the accumulator may comprise a part. The accumulator may comprise conveying means, such as a conveyor belt, which can be positioned in order to load and/or unload product onto a shelf on the container, the shelf being in either a protruding or retracted position in the shelf assembly.

There may also be provided means for automatically identifying product stored in a container. For example, in one embodiment, container 20 comprises a product identifying means such as a barcode reader or a read/write RFID device. This may be positioned on or near shelf 55 since product is typically loaded and unloaded near shelf 55. When product is loaded onto a tray, it is scanned on the product identifying means and this information is written to a memory device or means. This information is then used to identify the products contained within container 20 or locate particular products, for example.

Lifting device 50 and/or container 20 may be provided with a display means and/or an operator interface for displaying and editing the product identification information provided. Those skilled in the art will appreciate the variety of functions such an interface and display may provide to a user.

In one embodiment, a shelf identifier is provided when the product is scanned. For example, when a product is scanned and placed on the top shelf, a 'shelf #1 ' identifier is provided to associate that product with storage on the top shelf, which is designated as 'shelf #1 '. This provides more accurate information on the location of the product than just which container it is in. Anyone wanting to retrieve a particular item from a container can provide the identification of the required product, for example, by scanning in an identical product, and as a result the lifting mechanism can automatically raise shelf assembly 1 to the appropriate height for unloading of that product. Product identification means can also be used to locate a particular product contained in one container out of many containers in a particular location, for example a retail store warehouse.

By storing details of all the products stored on one or more containers, an inventory can be readily produced with details of all the product items. It can be seen that such a system could provide significant advantages, for example where an inventory check needs to be carried out when containers are delivered to a location. Instead of manually checking everything that is on the delivery inventory is indeed present in the containers, an automatic inventory based on scanned products can be generated, which can be easily and quickly checked, for example electronically.

In one embodiment, a location detection device is provided such that the lifting mechanism is adapted to raise and lower shelf assembly 1 in accordance with a received location-based signal. The signal may be received from a manually operated control device, such as a control pad having 'up' and 'down' buttons. Alternatively or additionally, the signal may be based on an alternative signal generating means. For example, the container may include means for detecting its location within a retail store environment. Many retail stores include means for tracking the location of shopping trolleys, for example, and it is envisaged that these location systems, or a similar system, may be used in conjunction with containers according to the invention. If a container has a shelf with milk on it and the container is wheeled to the milk aisle in a supermarket, for example, the container can detect that it is near the milk section and position shelf assembly such that the shelf with milk on it is positioned adjacent to shelf 55 such that the milk can be unloaded and stacked on the shelves.

Product may be stacked on a container in accordance with the location of product at the end user location. For example, retail product that is all located in a particular supermarket aisle is stacked in the same container. This clearly makes it simple and quick for someone to unload product onto the supermarket shelves.

Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise", "comprising", and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is to say, in the sense of "including, but not limited to".

The entire disclosures of all applications, patents and publications cited above and below, if any, are herein incorporated by reference.

Reference to any prior art in this specification is not, and should not be taken as, an

acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in the field of endeavour in any country in the world.

The invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features. Wherein the foregoing description reference has been made to integers or components having known equivalents thereof, those integers are herein incorporated as if individually set forth.

It should be noted that various changes and modifications to the presently preferred

embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be included within the present invention.

Claims

CLAIMS:

1. Product distribution apparatus comprising a container and shelf assembly, the container being adapted to accommodate the shelf assembly, the shelf assembly comprising a plurality of vertically spaced and laterally moveable shelves, and wherein the shelf assembly is vertically moveable relative to the container such that the shelf assembly may be raised and lowered to provide access to each of the shelves.

Apparatus as claimed in claim 1 , wherein adjacent shelves define a space

therebetween, product(s) stored within the space being substantially supported and/or protected by the portions of the product distribution apparatus surrounding the space.

Apparatus as claimed in claim 1 or claim 2, adapted to be used in a product distribution system wherein product is distributed to a distribution end facility, the product distribution apparatus, or at least one or more of the shelves thereof, being passed via a plurality of intermediary facilities and/or parties before arriving at the distribution end facility.

Apparatus is claimed in any one of the preceding claims, wherein the container has a mouth, and access to a shelf is provided when the shelf is positioned above the mouth of the container.

Apparatus as claimed in any one of the preceding claims, wherein the shelf assembly may be selectively and/or progressively moved to access particular products stored on the shelves.

Apparatus as claimed in any one of the preceding claims, wherein the shelf assembly comprises shelf support members for supporting the plurality of shelves. More preferably, the shelves are adapted to laterally slide on the shelf support members.

Apparatus as claimed in any one of the preceding claims, wherein the shelf assembly comprises side members upon which the shelf support members are mounted.

8. Apparatus as claimed in any one of the preceding claims, wherein the product

distribution apparatus comprises a product identifying means.

9. Apparatus as claimed in claim 8, further comprising memory means for storing product identification information read by the product identifying means.

10. Apparatus as claimed in claim 9, wherein the memory means is adapted to store

information relating to the location of a product carried by the apparatus.

11. Apparatus as claimed in any one of the preceding claims, wherein the product

distribution apparatus comprises a lifting mechanism for moving the shelf assembly relative to the container.

12. A lifting device for lifting the shelf assembly of the product distribution apparatus

according claim 1 the lifting device comprising:

13. A lifting device as claimed in claim 12, the lifting mechanism is adapted to move to a plurality of preset positions

14. A lifting device as claimed in claim 13, wherein the preset positions correspond to

positions of shelves of the shelf assembly in relation to the open upper side of the container. 15. A lifting device as claimed in any one of claims 12 to 14, including control means for controlling movement of the lifting mechanism.

16. A lifting device as claimed in any one of claims 12 to 15, wherein the lifting mechanism comprises:

a gantry;

a lifting arm adapted to be raised and lowered; and

an engagement mechanism for engaging with the shelf assembly.

17. A method for distribution of products, the method comprising:

placing the products on one or more shelves; moving the or each shelf laterally into a shelf assembly adapted to comprise a plurality of vertically spaced shelves;

transporting the container to a destination; and

18. A method as claimed in claim 17, wherein the step of placing the products on the shelf occurs before or after the step of moving the shelf into the shelf assembly.

19. A method as claimed in claim 17 or claim 18 comprising receiving an order for products and placing products on the shelf based on the order. 20. A method as claimed in claim 19, including retaining the products on the shelf and/or in the container from the step of placing the products on the shelf based on the order until removal of the products from the shelf by a distribution end party or at a distribution end facility. 21. A method as claimed in any one of claims 17 to 20 including placing products in the

container in an order corresponding to the order they will be removed from the container.

22. A method as claimed in any one of claims 17 to 21 including using the removed shelf with or as retail shelving.

23. A method as claimed in claim 22, including using the removed shelf as a retail shelf.

24. A method as claimed in any one of claims 17 to 23, including progressively or selectively moving the shelf assembly to a plurality of heights suitable for removing products and/or shelves from the container.

25. A method as claimed in any one of claims 17 to 24, including identifying products being placed on the shelf and/or in the container. 26. A product distribution system comprising: a shelf assembly comprising a plurality of shelves adapted to be positioned in the shelf assembly in a vertically spaced arrangement;

a loading facility for loading product to be distributed onto the shelves; and transportation means for transporting the container from the loading facility to a distribution end facility,

A product distribution system as claimed in claim 26, wherein the shelf assembly is moveable relative to the container such that the shelf assembly may be raised and lowered to provide access to each of the shelves.

A product distribution system as claimed in claim 26 or claim 27, wherein the product distribution system comprises intermediary distribution facilities, product being retained on the shelves and/or in the container at the intermediary distribution facilities.

Product distribution apparatus substantially as herein described with reference to any embodiment shown in the accompanying drawings.

A lifting device substantially as herein described, with reference to any embodiment shown in the accompanying drawings.

A method for distribution of products substantially as hereinbefore described, with reference to any embodiment shown in the accompanying drawings.

32. A product distribution system substantially as hereinbefore described, with reference to any embodiment shown in the accompanying drawings.