WO2012027416A1

WO2012027416A1 - Method and apparatus for in-carton display and fronting of merchandise items

Info

Publication number: WO2012027416A1
Application number: PCT/US2011/048874
Authority: WO
Inventors: Scott Duff; James Garth Close
Original assignee: Scott Duff; James Garth Close
Priority date: 2010-08-23
Filing date: 2011-08-23
Publication date: 2012-03-01

Abstract

A coiled spring drives a pull member along a guide to automatically front items in a display carton as items are removed. The guide is inserted through the rear of the carton under the items, and may be secured to the carton. A thin, tapered, or bevelled front tip of the guide is oriented to facilitate insertion of the guide below merchandise items. The guide may be fixed length or telescoping, and may be attached to the shelf before or after insertion into the carton. A shelf extension element may be provided so that the guide may slide along the shelf extension element to permit the guide to be pulled forward for insertion into a carton, or to permit a single guide to be used effectively on multiple shelf depths. Amounting bracket may allow either the guide or shelf extension element to be laterally adjusted, to pivot, and to breakaway.

Description

TITLE: Method and apparatus for in-carton display and fronting of merchandise items

INVENTORS: Scott Duff and James Garth Close

RELATED APPLICATIONS

This application is related to U.S. Provisional Patent Application No. 61/376,198 filed August 23, 2010 and claims the benefit of that filing date.

BACKGROUND OF INVENTION

The invention relates to the in-carton display of merchandise items such as those packaged in bottles, jars, cans, pouches, envelopes, and boxes, and more particularly to devices and methods in which merchandise items displayed in a carton can easily be moved forward by a spring driven device for improved visual exposure and effortless selection by consumers.

BACKGROUND OF INVENTION

Retail stores are cutting labor costs associated with stocking and fronting by requiring suppliers to provide retail ready packaging which displays their merchandise items in the same shipper boxes in which the product arrived at the store.

Retail stores recognize the importance of displaying products near the front edge of display shelves so that the merchandise items can be readily seen by consumers and easily reached by the customers. Customers typically remove products from the front of a carton. Those merchandise items remaining toward the rear of the carton may become difficult to see or to reach, and sales may be lost if products are not readily visible or have fallen over.

The retail store must then either spend labor costs to re-arrange and front the remaining merchandise items, or choose not to thereby losing sales and maintaining a cluttered store appearance.

As more merchandise items are merchandised directly from cartons, there is a growing need to provide an effective solution for automatic alignment of items in a display carton.

PRIOR ART

US Patent Application No. 11/623,397 filed January 16, 2007 describes alignment devices for in- carton display. That application is incorporated by reference into this specification.

The '397 application describes an example alignment device such as shown in FIGs. 1A-1F.

FIG. 1 A is a front perspective view of prior art assembled spring alignment device 101 with a guide 120, a spring 130, a handle 140, and a rear pull member 150.

FIG. IB is a front perspective view of the guide 120 of FIG. 1A showing a tapered front edge 122, a first side rail 124, a second side rail 126 and a rear end 127. FIG. 1C is a side view of the spring 130, and the rear pull member 150 of the guide 120 of FIG. 1A. In this example, the rear pull member includes a pull plate 151, first side extension 152, a second side extension 153, and a spring retention element 154. In other examples, the rear pull member may be a single plate, frame, looped wire, or other element which engages merchandise items as discussed below. In this example, the spring 130 has a first end 132 which is attached in proximity to the front edge of the guide as shown in FIG. 1A. The first end of the spring is bent in order to form a hook 134 which may engage the front edge of the guide between the first side rail 124, and the second side rail 126. The spring also includes a coiled portion 136 which acts on the rear pull member.

FIG. ID is a front view of the rear pull member 150 of Fig. 1A showing a pull plate 151, first side extension 152, a second side extension 153, and a base 155. In this example, the base 155 slides along the guide 120 between the first side rail 124 and the second side rail 126. In other embodiments, the coiled portion of the spring may serve as a rear pull member without a separate pull plate.

FIG. IE is a cross section view of the guide of FIG. IB showing a bottom portion 128, a first side rail 124, and a second side rail 126. In this example, the side rails are each open channels which serve to contain the base 155 of the rear pull member. FIG. IF is a front perspective view of the handle 140 of FIG. 1A showing an upright portion 142 and a base portion 144, where the base portion is inserted between a first side rail 124 and the second side rail 126 at the rear end 127 of the guide 120. In the example, the handle serves as a rear stop for the rear pull member. In other examples, the alignment device may be provided without a handle. The alignment mechanism may have scribed partition marks, such as at 1" intervals, in the rear of the guide to permit the guide to snapped off or cut to a desired length for a particular carton length or shelf width.

The '397 application describes an example carton and alignment device such as shown in FIGs. 2A-2B.

FIG. 2A is a side perspective view of a merchandise carton 200 having a front portion 201, a front end 202, a first side 204, a second side 206, a rear end 208, a bottom 210, and a top 212. In this example, a portion 214 of the front end 201 has been removed to expose merchandise items 230. In this example, the merchandise items are spice bottles. FIG. 2B is a side perspective view of one embodiment of an assembled spring alignment device 101 with a guide 120, spring 130, handle 140, and rear pull member 150. In this example, the guide includes an anchor 129 which engages an anchor slot 211 in the bottom 210 of the carton. In this example, the anchor slot was removed from the carton, such as with perforations. In other examples, the carton may be provided with the slot. In this example, the rear of the cartoon has been opened to permit insertion of the spring alignment device 101. In other examples, only a portion of the rear of the carton may be removed or opened in order to insert an alignment device.

Advantages of the alignment device include improved ease of installation, an approach that can be used with most items in a supermarket, reduced labor costs from the elimination of item handling, and shelf space savings.

FIG. 2C shows the spring alignment device 101 of FIG. 2B partially inserted into the carton 200 of FIG. 2A.

FIG. 2D shows plurality of merchandise items 230 removed from the carton 200, and the rear pull member 150 pushed near the front of the carton 200. In this example, the merchandise items have rounded bottoms and alignment device can be pushed underneath the items, so it is not necessary to support the merchandise items on carton rails in order to insert the alignment device underneath the items. In other examples as discussed below, the merchandise items are supported by a pair of rails or other features in the bottom of the carton so that the alignment device may easily be inserted under the items.

The '397 application describes a spacer insert such as shown in FIGFs. 3A-3D.

FIG. 3 A shows a side top perspective view of an alignment device 103 on a spacer insert 400. In this example, the spacer insert is designed to be inserted into the bottom of a carton before merchandise items are placed in the carton. The spacer includes a bottom portion 402, a first elevated side support 404, and a second elevated side support 406. In this example, the elevated side supports are slightly taller than the alignment device guide so that the guide may easily be inserted under the merchandise items 230. FIG. 3B is a front view of the alignment device, the spacer insert 400, and a carton 200. FIG. 3C is a rear perspective view of an alignment device partially inserted into the rear of a carton with a spacer insert 400, and merchandise items 230. FIG. 3D is a rear perspective view of the alignment device inserted into the rear of the carton. The spacer insert is typically fabricate from cardboard, but may be formed of a plastic or other material.

The '397 application describes an example rear tab such as shown in FIGs. 4A-4C.

FIG. 4A is a rear perspective view of a carton 200 which includes support rails 220 and 221 (not shown) for supporting merchandise item pouches 280 above the carton bottom; and an alignment device 102. The carton includes a perforated fold down rear slot 222 which includes a stop block 205. FIG. 4B shows the alignment device 102 partially inserted into the carton 200 through the rear slot 207. FIG. 4C shows the alignment device inserted into the carton and held in place by the stop block 205.

In FIG. 5, EP o. 0987971 to Vosshenrich shows a spring alignment device (3,6, 10 and 11) with the front portion 10 attached to a shelf 12. A carton with a rear and bottom slot is inserted over the alignment device.

SUMMARY OF THE INVENTION

The current invention relates to a device, system and method for displaying and re-aligning products in a display carton.

In one embodiment , the system and methods use a spring to drive a pull member along a guide to automatically front items in a display carton. A carton of multiple merchandise item containers, such as product pouches, bottles, cans, or boxes, is automatically aligned with a spring alignment device which provides a pressure to pull or push remaining item containers forward in the display carton as items are removed by customers.

In some embodiments, the guide is inserted into a carton before the carton is placed on a display surface such as a grocery shelf. In other embodiments, the guide is positioned on or secured to a display shelf, and the carton is inserted onto the guide.

The guide is typically inserted through an opening in the rear of a carton in a manner that a pull member engages the rearmost item container in the carton and pushes a row of items forward as an item is removed from the front of the carton by a customer. In one embodiment of the current invention, a carton of multiple merchandise item containers, such as product pouches, bottles, cans, or boxes, is automatically aligned with a spring alignment mechanism which provides a pressure to pull or push remaining item containers forward in the display carton as items are removed by customers.

In one embodiment, a standard shipping or display carton is modified to permit removal of a portion of the carton rear in order to insert the alignment device. In another embodiment, the carton is shipped with a rear access provided so that no carton modification is required at a retail site. In another embodiment, rear flaps or doors are opened to create rear access to insert the alignment device.

In some embodiments, the carton does not have support rails or a bottom slot; and a guide is inserted through a rear slot or opening and positioned under merchandise items. In other embodiments, the carton is modified to provide product support rails to elevate the items off of the bottom of the carton. In one example, rails may be provided as folded flaps which are part of a carton or box blank. In another example, carton inserts, such as cardboard, may serve as rails. In another example, the major flaps are folded above the minor flaps and have elevation features, such as crimps, that serve to elevate merchandise items above the bottom of a carton. In another example, where minor flaps are folded above the major flaps and would create an uneven bottom carton surface, a portion of the minor flaps may be omitted or indented in order to create a channel for the guide. In another example, the bottoms of merchandise items have slots or pedestals to permit insertion of a guide under the merchandise items.

In one embodiment, the carton is modified to permit removal of a small portion of the bottom or front of the carton in order to provide an anchoring slot for the alignment device or it is shipped with an opening. In another embodiment, the guide is anchored to the walls or sides of the rear port or opening of the carton. In other embodiments, drag or friction between the guide and the carton is increased by placing putting sandpaper, friction tape, rubber, or other friction enhancement elements on the underside of the guide. Friction can also be enhanced mechanically by roughening or by adding features such as bumps or ridges to the underside of the guide to resist sliding on the carton. A hinge or spring in the shelf attachment may also be provided to increase the pressure between the underside of the guide and the floor of the carton to increase friction. In another example, the guide includes a clip to latch the guide to the bottom of the carton. In another example, the guide includes one or more prong which grips the floor of the carton.

In one embodiment, the front tip of the guide is thin, tapered, or bevelled, and oriented to facilitate insertion of the guide below merchandise items. In one example, the tip is thin and curved in order to create a spring effect with downward bias so that the tip will tend to travel along the bottom of the carton as it is inserted. The tip also acts as a ramp to lift or elevate the merchandise items from the floor of the box onto the guide. In other examples, the tip includes a roller or climber feature.

In one embodiment, a guide elevation feature is placed on the underside of the guide so that the front tip is elevated to make it easier to insert the carton onto the guide. In one embodiment, a shelf extension element is provided so that the guide may slide along the shelf extension element to permit the guide to be pulled forward for insertion into a carton, or to permit a single guide to be used effectively on multiple shelf depths. In one example, the front tip of the guide may be pulled out past the front edge of the shelf to permit it to be more easily inserted into a carton. In one example, the guide of a spring alignment device is inserted into a carton and then the carton and guide are moved to the rear of the shelf to permit extra items to be placed in front of the carton. After the extra items are removed, the carton and guide may be pulled forward, so that the guide slides forward with respect to the shelf extension element. In one example, the friction between the guide and the shelf extension element is designed to provide a desired sliding resistance.

In one embodiment, the rear of the shelf extension element is anchored to or restrained by the shelf or rear wall of a shelf. In another embodiment, the guide is inserted onto the shelf extension element, and the front portion of the shelf extension element is attached to the shelf. In some examples, the lateral position of the shelf extension element may be adjusted to a desired position. In other embodiments, the guide is attached to the shelf or rear wall of the shelf, and no shelf extension element is provided. In various examples, anchoring techniques include clips, screws, bolts, or pins inserted through shelf holes; magnets; adhesives; shelf clips; freezer rack clips; and wedging elements between the shelf and rear wall. Anchoring brackets may have lateral and vertical pivoting capability, and may be provided with a breakaway feature to reduce breakage and to be able to take the guide and extension off for reasons such as cleaning.

In other embodiments, the extension may be relatively short so that is is secured to the middle portion of the shelf to permit the guide to slide forward and backward. In another embodiment, the guide is tethered to the shelf or rear wall.

In another embodiment, a telescoping guide is used so that the guide can be used in cartons of various lengths. One example would be a two piece guide where the pieces slide relative to one another. The two pieces may or may not have a locking mechanism to set and maintain their combined length.

The current invention supports effective product rotation and first in/first out inventory management.

Merchandise items are not removed from display cartons, so older merchandise items are not forced to the rear of a shelf behind newer items.

BRIEF DESCRIPTION OF FIGURES FIGs 1 -5 are prior art.

FIG. 1 A is a front perspective view of a prior art alignment device.

FIG. IB is a front perspective view of the guide of FIG. 1A.

FIG. 1C is a side view of the spring and the rear pull member of the guide of FIG. 1A.

FIG. ID is a front view of the rear pull member of the guide of Fig. 1A.

FIG. IE is a cross section view of the guide of FIG. IB.

FIG. IF is a front perspective view of the handle of FIG. 1A

FIG. 2A is a side perspective view of a prior art merchandise carton. FIG. 2B is a side perspective view of one embodiment of an assembled spring alignment device to be inserted into the carton of FIG. 2A.

FIG. 3 A is a front perspective view of a prior art alignment device and spacer insert.

FIG. 3B is a front view of the alignment device, the spacer insert, and a carton.

FIG. 3C is a rear perspective view of an alignment device partially inserted into the rear of a carton with a spacer insert.

FIG. 3D is a rear perspective view of the alignment device inserted into the rear of the carton.

FIG. 4A is a rear perspective view of a prior art carton with support rails and a fold down rear slot; and an alignment device.

FIG. 4B shows the alignment device of FIG. 8 A partially inserted into the carton through the rear slot.

FIG. 4C shows the alignment device of FIG. 8 A inserted into the carton.

FIG. 5 is a top perspective view of a prior art alignment device where a carton with a bottom slot and rear slot is inserted over a spring alignment device.

FIG. 6 is a front perspective view of an alignment device having a guide with side wings for engaging the rear wall of a carton, a front tip, and a rear pull member; a shelf extension element; and a laterally adjustable extension element mounting bracket with a pivoting and breakaway capability.

FIGs. 7A-C are top views of the rear portion of the alignment device of FIG. 6. FIG. 7A shows guide fully extended on the shelf extension element. FIG. 7B shows the guide partially extended along the shelf extension element. FIG. 7C shows the guide pushed back with no extension along the shelf extension element.

FIG. 8 is a rear exploded perspective view of the extension element mounting bracket, bracket pivot element, shelf pin, and pivot pin of FIGs. 7A-7C.

FIG. 9 is a top view of a guide with a rear anchor comprising a plurality of tines.

FIG. 10A is a rear perspective view of a carton or tray which may be opened in the rear.

FIG. 10B is a rear perspective view of the carton of FIGF. 10A with a first tab opened.

FIG. IOC is a rear perspective view of the carton of FIGF. 10A with a first tab and second tab opened and rail extensions folded down.

FIG. 10D is a rear perspective view of a carton or tray of FIG. 1 OA with merchandise items, with the rear wall closed.

FIG. 10E is a rear perspective view of a carton or tray of FIG. 1 OA with merchandise items, with the rear wall open so that merchandise items can be pushed rearward in order to accommodate extra items in the front of the box.

FIG. 11 A is a front perspective view of a partially folded carton blank with integral rails formed by the major flaps and extended minor flaps.

FIG. 11B is a top view of the open assembled carton of FIG. 11A.

FIG. llC is a bottom view of the assembled carton of FIG. 11A where the minor flaps have angled ends. FIG. 1 ID is a front perspective view of a partially folded carton blank with integral rails where the minor flaps have the same length as the major flaps.

FIG. HE is a top view of the open assembled carton of FIG. 11D.

FIG. 12A is a side perspective view of a rear pull member position indicator where the rear of the alignment device is too far left relative to the carton. FIG. 12B is a side perspective view of a rear pull member position indicator if FIG. 12A where the rear of the alignment device is too far right relative to the carton.

FIG. 12C is a side perspective view of a rear pull member position indicator if FIG. 12A where the rear of the alignment device properly positioned relative to the carton.

FIG. 13A is a top perspective view of tray with pre-formed rear access port and front slot.

FIG. 13B is a top perspective view of the tray of FIG. 13A with cardboard rail inserts.

FIG. 13C is a cross section view of the tray of FIG. 13B.

FIG. 14A is a top side perspective view of a depth-adjusted guide of alignment device affixed to or positioned on the top surface of a shelf.

FIG. 14B shows the alignment device of FIG. 14A with a carton or tray positioned at the front of the guide. FIG. 14C shows the carton of FIG. 14B positioned over the alignment device. The tip of the guide retains the front of the carton.

FIG. 14D shows the carton of FIG. 14C with some merchandise items removed.

FIG. 14E shows the carton of FIG. 14D with extra merchandise items placed on top of the carton or tray.

FIG. 15A is a side view of a guide with a guide extension in a first extended orientation,.

FIG. 15B is a side view of the guide and guide extension in a second contracted orientation.

FIG. 15C is a top view of a guide, guide extension, and shelf extension element.

FIG. 16A is a side view of a tip with an offset portion in the tip base.

FIG. 16B is a front perspective view of a tip with inset sides which are designed to engage the sides of a slot in the front of the carton.

FIG. 16C is a side view of a tip with a prong to engage the carton bottom.

FIG. 17 is a top view of an alternative shelf extension element mounting bracket with a pivot pin and a slot breakaway feature.

FIG. 18 is a top perspective view showing the rear portion of a guide of an alignment device bent downward to fit between a shelf and a rear wall.

FIG. 19A is a side view of an alignment device partially inserted in a carton.

FIG. 19B is a top view of an open carton with an anchor anchor slot.

FIG. 20 is a front perspective view of an alignment device with a shelf extension element having an integral mounting bracket.

FIG. 21 is A-21 J show exploded side and bottom views of a pusher element and a shelf extension element. FIG. 21 A is a side view of a pusher element with a tapered front end and a rear puller element.

FIG. 21B is a side view of a guide for the pusher element of FIG. 21A.

FIG. 21C is a bottom view of the pusher element of FIG. 21A. showing an shelf extension element retention slot.

FIG. 2 ID is a bottom view of a shelf extension element showing an engagement element for the retention slot of FIG. 21C.

FIG. 2 IE is a side view of a shelf extension element of FIG. 2 ID.

FIG. 2 IF is a detailed side view of an shelf extension element retention slot and engagement element.

FIG. 21G is a rear view of the rear pusher element of FIG. 21A with a shelf extension element inserted over the guide.

FIG. 21H is a rear view of the rear pusher element of FIG. 21A without a shelf extension element inserted over the guide. FIG. 211 is a rear view of the guide of FIG. 21A.

FIG. 21 J is a rear view of a shelf extension element placed over the guide of FIG. 21 A.

FIG. 22A is a side view of an alignment device with a shelf extension element being positioned on a display shelf.

FIG. 22B is a side view of the pusher element with a shelf extension element of FIG. 22A.

FIGs 23A-23D show the placement of a carton on pusher device and shelf extension element assembly.

FIG. 23A shows a carton positioned for insertion over the pusher guide.

FIG. 23B shows the carton partially inserted over the pusher guide.

FIG. 23C shows the carton inserted over the pusher guide and pushed to the rear of the shelf so that extra

merchandise items may be placed in front of the carton.

FIG. 23D shows the extra merchandise items removed and the carton pushed or pulled to the front of the shelf. FIG. 24 is a side view of a pusher element with a rear pusher element and coil spring, with a shelf extension element being positioned on a display shelf.

DESCRIPTION OF EMBODIMENT - Definitions

In this specification, the term "ahgnment device" means a spring-drive device which pushes or pulls merchandise items forward in a carton or tray.

In this specification, the term "spring alignment device" means an alignment device where a coiled spring drives merchandise items. The spring may act directly on the merchandise items, or may drive a rear pull element which engages the merchandise items.

In this specification, the term "shelf broadly refers to a grocery shelf and to other types of product display surfaces, including tables, end or aisle displays, and other boxes or cartons. Examples of a shelf include a gondola or a wire rack, such as a freezer shelf.

In this specification, the term "guide" means a base portion of an alignment device. The guide functions to insert the ahgnment device into a carton, and most or all of the guide is typically inserted into a carton. The guide may be flat and planar; may have vertical offsets to facilitate carton insertion; may include one or more hook, sidewing, wedge, or fin for engaging a rear wall of a carton; may include tab elements, prongs or friction additives to provide carton retention for the alignment device; may include one or more shelf retention elements. The guide may include scribes or markings for bending or length adjustment. The guide may include a slot or other feature to accept the front end of a spring. In some examples, the guide is a single section; and in other examples the guid emay have two or more sections that telescope.

In this specification, the term "guide extension" or "guide extension section" refers to a telescoping portion of a two-part telescoping guide.

In this specification, the term "shelf extension element" means an element which is placed on, attached to, or restrained in relation to a shelf or other display surface so that the guide may be moved forward or rearward relative to the shelf extension element. The guide, or a portion of the guide, typically slides in or on the shelf extension element. In one example, the rear portion of the shelf extension element is attached to or restrained on the shelf. In another example, the front of the shelf extension element is attached to the shelf.

In this specification, the term "shelf retention element" means a bracket, pin, screw, clamp, magnet, adhesive, or other means to attach the shelf extension element to shelf.

In this specification, the term "lateral adjustment element" refers to an element or combination of elements which provides the ability to move the shelf retention element, shelf extension element, the guide, or the carton laterally with respect to the shelf or display surface.

In this specification, the term "rear pull member" means any feature for engaging a merchandise item in order to push or pull the item forward in a carton.

In this specification, the term "box" and "carton" are used interchangeably and mean a container for displaying merchandise items. The carton is typically made of cardboard, but may be provided in other materials. The display carton may be the same as the shipping carton; or one or more display cartons may be shipped in a single shipping carton. The term carton includes shipper trays which are removed from a box and displayed on a shelf.

In this specification, the term "carton floor" refers to the inside bottom surface(s) of the carton. The floor may be a solid bottom, or may be formed by folded flaps.

In this specification, the term "retail ready packaging" or "retail ready carton" refers to containers and packaging for retail goods which are ready to be displayed instantly or with little set up by retailers for retail consumption by consumers. Typically, merchandise items are displayed on the shelf in the same shipper box in which they were delivered to the retail store.

In this specification, the term "tray" refers to a carton with an open top.

In this specification, the term "rear access port" means an opening in the rear wall of a carton, or the absence of a rear wall in the carton. The opening may be provided by the manufacturer; may be a perforated tab which is opened, folded, or removed; may be rear walls or flaps which are opened or removed; or may be a carton without a rear wall.

In this specification, the term "merchandise items" refers generally to packages of items or substances in cans, boxes, pouches, or other containers; and to unpackaged items. The items may be grocery or non-grocery items.

In this specification, the term "carton anchor" means one or more elements which are provided on the guide to engage a portion of the carton so that the guide and carton maintain a fixed position with respect to on another".

In a folded carton, the smaller length flaps are referred to as "minor flaps" and the longer flaps are referred to as "major flaps". In this specification, the term "guide front tip" refers to the front portion of the guide. The tip may be formed as part of the guide, or as one or more separate pieces which are attached to the guide base. One function of the tip is to facilitate inserting the guide into a carton and under merchandise items. Another function of the guide front tip is to lift or elevate the merchandise items from the box floor onto the guide. In some examples, additional features such as coiled spring attachment features or lateral adjustment elements are provided in the tip.

DESCRIPTION OF EMBODIMENT- spring alignment mechanism with guide and shelf extension element Multiple merchandise item containers, such as product pouches, are shipped to a retailer in a retail ready carton. The retailer inserts a spring alignment mechanism into the carton, so that the spring alignment mechanism provides a pressure to pull remaining merchandise items forward in the carton as merchandise items are removed from the carton by customers.

FIG. 6 is a front perspective view of an alignment device 606 with a guide 620 with side wings 624 and 624 for engaging the rear wall of a carton, a front tip 630 a rear pull member 150, a shelf extension element 640, and a laterally adjustable extension element mounting bracket 650 with a pivoting and breakaway capability. In this example, the side wings are formed by over-molding soft PVC side wings to the guide to achieve a desired friction with the rear wall of the carton. In this example, the side wings extend over a substantial portion of the guide length so that the wings can engage the rear wall cartons of various lengths. In this example, the wings are solid projections. In other examples the wings may have a plurality of fingers, tines, notches, or projections so that the rear carton wall is engaged between a pair of fingers or projections. The front portion of the wings include a lead-in taper 626 for ease of installation in the carton.

In this embodiment, the spring alignment system guide 620 travels with respect to the shelf extension element 640. The shelf extension element 640 is secured to the shelf with a extension element mounting bracket 650. The guide supports the front portion of a coiled spring 130 (not shown) so that a rear portion of the spring acts on a rear pull member 150 to pull remaining items forward as items are removed from the display carton. The shelf extension element 640 permits a desired positioning of the guide and carton on a display surface such as a shelf.

Example- rear wall anchor side wings to anchor guide in carton

In this example, the rear portion of the guide includes side projections or wings for engaging the rear wall of the carton. The wings may be provided in a variety of configurations such as wedges which may or may not be notched, compliant materials, or multiple finger or bristle projections. In various examples, the projections grip the walls of the rear opening either by interlocking fingers, bristles, flaps or ridges; by causing the box to compress and/or deform and bend around the wings; or by the wings deforming inward around the rear box opening. The lateral width of the guide with extensions is greater than the width of the rear carton opening. Various materials such as plastic, rubber, foam, sponge, etc. may be used. The use of an extended wing allows the same guide to be used with multiple box lengths. The wings may be fixed, or may be retractable or rotatable so that they are engaged after the guide is inserted into the carton.

FIG. 9 is a top view of a guide 620 with a rear anchor 637 comprising a plurality of tines 638. In other examples, notches or other features may be provided on the rear anchor wing. Example: shelf extension element with separate mounting bracket

FIGs. 7A-C are top views of the rear portion of the alignment device 606 of FIG. 6. FIG. 7A shows guide 620 (not shown) fully extended on the shelf extension element 640. FIG. 7B shows guide 620 partially extended along the shelf extension element 640. FIG. 7C shows guide 620 pushed back on the shelf extension element 640.

FIGs. 7A-7C show the extension element mounting bracket 650 with a shelf mounting pin 659 positioned in a the left lateral adjustment slot 651 . In this example, a second pin is typically inserted through the right lateral adjustment slot 652. In this example, the shelf extension element 640 is connected to the extension element mounting bracket 650 with a bracket pivot element 660 which includes a pivot pin 662 (not shown) that is inserted into a pivot slot 661 on the bracket, the bracket pivot element and pin permits the shelf extension element to be pivoted laterally and vertically; and provides a breakaway capability for the shelf extension element so that it can be deliberately removed for reasons such as cleaning, or in the event of excessive force it will disengage to avoid damage to the bracket or guide. In this example, the bracket pivot element slides over and snaps top the rear portion of the shelf extension element. In this example, rotation stops 665 are provided on the extension element mounting bracket 650 to limit the lateral rotation of the shelf extension element. In this example, the pivot pin 662 releases from the pivot slot 661 when excessive force is applied to the shelf extension element, thereby providing a breakaway feature 666.

FIG. 8 is a rear exploded perspective view of the extension element mounting bracket 650, bracket pivot element 660, shelf pin 659, and pivot pin 662 of FIGs. 7A-7C. In this example, the pivot pin snaps into the extension element mounting bracket 650, and permits lateral and vertical rotation. Lateral rotation is limited by rotation stops 665. The pivot pin also serves as a breakaway feature 666 for the shelf extension element.

FIG. 17 is a top view of an alternative shelf mounting bracket 680 with a pivot pin 682. A breakaway feature is provided by a slot 684 on the end of the shelf extension element 640.

FIG. 20 is a front perspective view of an alignment device with a shelf extension element 644 having an integral mounting bracket 690. inserting the guide into a carton

The guide portion 120 of the alignment device is typically inserted through the rear wall of the carton. Some examples of rear carton access include a rear access port 207 (FIG. 13 A) such as with a perforated tab; rear opening flaps 270, 272 (FIGs. 10A-10F); removing the rear carton wall; and providing a carton without a rear wall.

Insertion of the guide into the carton may be facilitated by techniques such as providing a channel in the carton between support rails; providing slots or pedestals on the bottom of merchandise items; and providing a guide tip to raise the merchandise items over the guide as the guide is inserted into the carton.

In one example carton loading method as illustrated in FIG. 23A-23D, the guide is pulled forward so that the front tip 630 of the guide 622 is near or in front of the front edge 307 of the shelf; and the guide tip is lifted slightly above the shelf. The guide may then be easily inserted into the carton 200. In one example, a bottom or rear wall anchor element on the guide secures the guide to the carton. The carton and inserted guide are pushed rearward to a desired location. The carton may be positioned in a desired location, such as with its front at the front edge of the shelf; or so that the front of the carton is restrained behind a short front fence on the shelf; or pushed further back on the shelf so that extra items may be placed in front of the carton

The merchandise item packaging may be adapted to facilitate guide insertion and operation. In one example, the items include bottom features, such as pedestals, that create a channel for positioning the guide. This approach can be used on heavier cans and jars, for instance, to reduce contact area and sliding friction on the carton bottom, and to eliminate most sliding friction relative to the guide.

In another example, pouches or cartons include bottom channel features. shelf extension element features

There are several techniques for using the shelf extension element. One method is to improve the ease of inserting a guide by permitting the guide and tip to be pulled to or past the front portion of the shelf for more convenient access. Another method is permitting the guide and carton to be pushed backward on shelf; and permitting the carton to be pushed to the back of the shelf to provide extra space for extra merchandise items on the shelf in front of the carton. This capability helps to support a "first in, first out" product rotation as well as system's ability to assist and speed up an inventory process.

FIG. 25G is a rear view of the alignment device 607 of FIG. 25 A with an shelf extension element 642 inserted into the guide 621. In other examples, the guide is inserted into a portion of the shelf extension element. FIG. 25H is a rear view of the rear pull element 150 of FIG. 25A without an shelf extension element inserted into the guide. FIG. 251 is a rear view of the guide of FIG. 25A.

FIG. 25 J is a rear view of an shelf extension element 642 placed over the guide of FIG. 25 A. In this example, the shelf extension element is a flat strip. In other examples, the shelf extension element may have other cross section shapes.

The rear portion of the shelf extension element is typically secured with respect to a display surface such as a shelf. In FIG. 6 an extension element mounting bracket 650 is provided. In FIG. 25, the shelf extension element includes a rear spring retention element 658 that is inserted between a shelf and a shelf wall.

Securing the extension element with respect to the shelf

In the example of FIG. 6 the extension element mounting bracket 650 secures the shelf extension element 640 to the shelf. In this example, the extension element mounting bracket includes a lateral adjustment element 651 and 652 (shown in FIG. 7C) which are slots to permit the bracket to be moved laterally along the shelf; a lateral pivot element, a pivot pin 662, which permits the shelf extension element to be laterally rotated by about 10-20 degrees, a vertical pivot element, a pivot pin 662 , which permits the shelf extension element to be raised above the shelf about 10 degrees. The pivot pin 662 is also a breakaway feature, which releases the shelf extension element when the pivot ranges are exceeded or when there is a large force applied to the shelf extension element. The breakaway feature also permits the shelf extension element to be removed for purposes such as cleaning, and then replaced in its mounting bracket. In this example, the pivot pin serves as both the pivot element and breakaway feature. In other examples, a separate breakaway feature may be used. In this example, the extension element mounting bracket provides a vertical offset of the shelf extension element and guide above the shelf.

In the example of FIG. 22, the spring alignment device 608 includes an shelf extension element which has a v- shaped compression element 657 which is positioned between the rear portion 305 of a shelf 300 and a rear wall 306 of a shelf, thereby retaining the shelf extension element. In other examples, the shelf extension element may be secured to the shelf or to the rear wall with other features such as with pins, bolts, snaps, magnetic attachment, adhesive attachment, etc. The shelf extension element can also be retained by other means, such as by adding foam to the rear of the shelf extension element and placing the foam between the rear of the shelf and the rear wall in order to create a wedging effect.

In other embodiments where a guide is provided without an shelf extension element, the guide may be attached to the shelf with a mounting bracket, v-shaped compression element, magnet, or other means. relationship of guide and shelf extension element

FIG. 25C is a bottom view of the guide 621 and rear pull 150 of FIG. 25A showing an shelf extension element guide retention slot 649. FIG. 25D is a bottom view of an shelf extension element showing a guide retention tab 648 for the retention slot of FIG. 25C. FIG. 25E is a side view of an shelf extension element 642 of the alignment device of FIG. 25D. FIG. 25F is a detailed side view of the shelf extension element guide retention slot 649 and the guide retention tab 648. In other examples the guide retention features may be modified or eliminated.

In the example of FIG. 22B, the alignment device guide 622 includes side rails 624 and 626, and the shelf extension element fits snugly between the side rails so that there is a friction force between the shelf extension element and the guide. In other examples, other engagement features such as holes and detents may be used to adjust the shelf extension element and the guide to a desired configuration.

FIGs 23A-23D show the placement of a carton 200 with respect to an alignment device 608 and shelf extension element assembly 643. FIG. 23A shows the carton 200 positioned for insertion onto the alignment device guide 622. In this example, the alignment device guide has a bottom button 631 which serves as an elevation feature for elevating the front of the guide above the shelf so that the front end of the guide is elevated over the bottom of the carton bottom. This slight elevation facilitates insertion of the guide in the carton. In other examples, other elevation methods may be provided. In other examples, no elevation is used. shelf placement adjustment and excess items

FIG. 23B shows the carton partially inserted over the alignment device guide 622. FIG. 23C shows the carton inserted over the alignment device guide and pushed to the rear portion of the shelf 300 so that extra merchandise items 231 may be placed in front of the carton 200. One aspect of the current invention is that it permits a single pusher element to be used on various sizes of shelves. For instance, a 16 inch long spring alignment device may be used on an 18 inch or a 21 inch shelf, or longer shelf. In this example, the carton and pusher guide are forced to the rear of the shelf so that extra items can be placed in front of the carton. This ability to place items in front of the carton preserves a "first in- first out" inventory rotation so that older items can be sold first.

FIG. 23D shows the extra merchandise items 231 removed and the carton pushed or pulled to the front portion 307 of the shelf. In other examples, the carton may be forced forward by the pusher spring until the front of the carton is restrained by a stop element placed on the shelf. guide

One function of the guide is to secure the front of a spring so that the spring may be positioned under merchandise items in a carton in order to pull a rear pull member 150 forward as merchandise items are removed from the carton. In some cases, the guide provides a track for the rear pull member.

The guide may be a c-shaped channel as shown in FIG. 1, so that the rear pull member will slide in the channel. In another example, the guide may be flat and rear pull member base 155 may overlap the sides of the guide. In other embodiments, the guide may be a simple flat base, and the spring or rear pull member may be positioned on the guide without lateral restraint.

In another example, the top of the guide is wider than the bottom of the guide in order to provide less obstruction from bottom flaps or other irregularities in the carton.

The guide may be sized so as to work specifically with a particular length box or sized so that one guide can work with multiple lengths of boxes. The guide may have scribing or markings to permit the base to be cut, broken, or bent to a desired length.

The guide may be longer than the carton. Extra length in the rear provides a grip for inserting the device into a carton, and provides flexibility for multiple box lengths. In other examples, a front portion of the guide extends outwardly from the carton through a front slot in the carton. securing the guide to the carton

Once the guide is inserted, it may be anchored to the box or carton. For example, the alignment device can be anchored or secured relative to the bottom, front wall or rear wall of the carton.

The guide may include an anchoring projection or other feature for engaging a portion the carton. An example of a bottom anchor element 137 and mating carton anchor slot 211 is shown in FIG. 19A which is a side view of an alignment device partially inserted in a carton. FIG. 19B is a top view of an open carton with an anchor slot 211. The alignment device includes an anchor stud 137 which engages the anchor slot. Device testing suggests that for bottom- supported alignment devices, anchor slots and elements positioned toward the rear of the carton are more effective than anchor slots and elements positioned toward the front of the carton. In another example, multiple holes, such as on a regular 2 inch (5 cm) spacing, may be provided in the guide, and anchor elements may be selectively inserted into one or more of the multiple holes. This approach permits use of the rear-most hole in a length-adjusted guide.

In another example, the bottom of the guide has a plurality of prong anchors, such as downward projections which dig into the carton floor.

In another example, a guide mounting bracket or extension element mounting bracket may include a hinge with a spring which exerts a downward pressure on the guide in order to increase friction between the guide and the carton floor.

In another example, the friction between the bottom of the guide and the carton is deliberately enhanced, such as by roughening the bottom surface of the guide, or by applying a tacky material such as soft rubber or plastic, tape, sandpaper to the carton floor or the bottom of the guide. In other examples, the bottom of the guide is modified by adding bumps or ridges to create a drag force between the bottom surface of the guide and the carton floor.

In another example, the tip engages a slot in the lower portion of the front of the carton. FIG. 16A is a side view of a tip 670 where an offset portion 672 in the tip base 671 is designed to engage a slot in the front of the carton. FIG. 16B is a front perspective view of a tip 674 with inset sides 675 and 676 which are designed to engage the sides of a slot in the front of the carton. FIG. 16C is a side view of a tip 677 with a prong 678 to engage the carton bottom.

In other examples, the guide may be retained at the rear of the carton with a rear wall engagement element which engages the rear portion of the carton; or with a clip which engages the rear wall or bottom of the carton. The guide may be retained at the rear of the carton with the use of side wings which engage the front of the rear carton wall in order to prevent the guide from being pushed backwards. These wings may be retractable or rotatable so that they are engaged after the guide is inserted into the carton.

In another example, a clip is provided to attach the guide to the rear wall or rear portion of the carton bottom. The clip may be integral to the guide, or may be a separate element.

In another example, the guide may include one or more magnets to help restrain the carton from movement relative to the shelf. In the case of a relatively thin carton bottom, a magnet can provide an effective force through the carton material.

Example- inserting guide into carton

In one example carton loading method as illustrated in FIG. 23A-23D, the guide is pulled forward so that the front tip 630 of the guide 622 is near or in front of the front edge 308 of the shelf; and the guide tip is lifted slightly above the shelf. The guide may then be easily inserted into the carton 200. In one example, a bottom or rear wall anchor element on the guide secures the guide to the carton. The carton and inserted guide are pushed rearward to a desired location. The carton may be positioned in a desired location, such as with its front at the front edge of the shelf; or so that the front of the carton is restrained behind a short front fence on the shelf; or pushed further back on the shelf so that extra items may be placed in front of the carton.

Restraint of carton on display surface

In some cases, it is desirable not to require attachment of the alignment device to a shelf. One reason to avoid attachment is to provide more convenient insertion of the alignment device before the carton is placed on the shelf. Another reason is the ease of placement and re-positioning on the shelf. In various examples, the carton may be restrained from being pushed forward by the alignment device. Examples of carton restraint methods include tape or adhesive on the bottom portion of the carton, magnetic tape on the bottom portion of the carton, and mechanical stops such as pins or tabs inserted into the shelf.

In other examples, a front shelf railing or fence may be provided to prevent forward movement of the carton.

In the guide front anchor example described above, the front anchor secures both the guide and the carton to the shelf. guide front end and tip design

The tip of the guide is typically designed to facilitate insertion of the front end of the guide under a row of merchandise items. As the guide is inserted into the carton, the tip travels under merchandise items and lifts the items from the carton floor onto the guide. The tip may be a general purpose design, or it may be optimized for various types of packaging such as pouches or boxes. In some cases, an additional function of the tip is to assist in anchoring the guide to a shelf or the front of a carton. The tip may be attached to the guide or integral to guide.

In the example of FIG. 6, a thin tip 630 is attached to the front of the guide 606. In this example, the tip has a downward bias so that it tends to ride along the carton bottom and lift the merchandise items as the guide is inserted.

In one example, the leading edge of the tip can be a thin roller, such as a baking rolling pin which is designed to diminish friction or hanging up while moving on the floor of the carton and to assist to provide lift for elevating the merchandise items onto the guide.

In this example, there is a climber roller tip with two paddles offset 180 degrees. The paddles are very short and when one hits an edge (such as the front minor flap), it flips and rolls and the second paddle rolls over onto the top of the edge. spring retention

In some examples, the front portion of the spring is retained in a slot in the guide or tip, such as by providing a z-shape bend in the front of the spring. In other examples, the front portion of the spring is mechanically or adhesively adhered to the guide or tip. rear pull member Referring to FIG. 24, the rear pull member typically includes a base 155 which slides along the guide 120, and a pull plate 151. The pull plate may include a first side extension 152, and a second side extension 153 as shown in FIG. 1C. The base may include features which grip the guide as shown in FIG. 24, or the base may travel between guide rails, or the base may not be constrained by the guide. In one example, the coiled portion of the spring may serve as a rear pull member without a separate pull plate.

FIGs. 12A-12C is a side perspective view of a rear pull member position indicator or flag 156. In another example, electronic position indicators may be used on guides to automatically communicate inventory information.

DESCRIPTION OF EMBODIMENT- spring alignment mechanism with telescoping guide

In this embodiment, the guide has a first portion which slides relative to a second portion so that the guide may telescope to fit various lengths of cartons. This feature permits one guide to be used with several different carton sizes without having excess guide length extend past the rear or front of a carton, and permits the carton to be pushed to the rear wall of a shelf.

The guide may have a feature to lock the guide at a desired length, so that the length is permanently fixed or re- adjustable. This guide may be used with any box anchoring mechanism, with or without shelf retention of the guide, and with or without a shelf extension element.

FIG. 15A is a side view of a guide 710 with a guide extension 720 in a first extended orientation, so that the guide extension 720 is pulled outward from the guide 710. In this example, a guide extension locking feature 721 engages the guide to secure the extension in a desired configuration. FIG. 15B is a side view of a guide 710 with a guide extension 720 in a second contracted orientation, so that the guide extension 720 is pushed into the guide 710. FIG. 15C is a top view of a guide 710, guide extension 720, and shelf extension element 640.

DESCRIPTION OF EMBODIMENT- spring alignment mechanism with guide

In this embodiment, a guide is provided without an shelf extension element, and the guide is secured to the shelf.

FIG. 18 is a top perspective view showing the rear portion 521b of a guide of an alignment device 504 bent downward to fit between a shelf and a rear wall.

The guide may be attached to or positioned on a shelf or support surface. The attachment may be by a variety of methods including magnetic, adhesive, and mechanical, such as pins. In one example, the alignment device is cut or bent or a desired length, and is positioned on a shelf so that the rear of the base is retained by a rear wall of the shelf. A bend may extend upwards, downwards to the space between a shelf and a rear wall, or sideways. In this type of application the alignment device is restricted from moving backwards by the shelf wall, and it is not necessary to affix the alignment device to a shelf.

FIG. 14A is a top side perspective view of a depth-adjusted guide 520 of alignment device 501 affixed to or positioned on the top surface 304 of a shelf. In one example, the rear of the base is retained by the rear wall of the shelf. A portion 521b of the rear of the guide has been removed, and portion 521a remains. FIG. 14B shows the alignment device of FIG. 14A with a carton or tray such as 200 is positioned at the front of the guide. FIG. 14C shows the carton of FIG. 14B positioned over the alignment device. The tip 123 of the guide retains the front of the carton as discussed above. FIG. 14D shows the carton of FIG. 14C with some merchandise items removed. FIG. 14E shows the carton of FIG. 14D with extra merchandise items placed on top of the carton or tray.

DESCRIPTION OF EMBODIMENT- carton and carton modifications

One aspect of the current invention is to ship and display merchandise items in a carton without requiring that items be removed and placed on a shelf or in a display. The carton is typically modified to permit insertion of a guide through the rear of the carton, and to permit easy removal of portions of the carton for product display or guide insertion. Additional possible modifications include guide anchoring features and product supports or support features on the bottom of the carton.

The carton typically has all or portion of two side walls; a bottom or partial bottom; a front wall and a rear wall with an opening in the rear wall. In some examples, the rear wall is removed, or the carton is provided without a rear wall.

In some examples, the top of the carton is removed, or the carton is provided without a top, such as with shrink wrapping. In other cases, a portion of the carton top is removed. The carton may be shipped and displayed with a closed top, an open top tray, or a partially opened top. The carton may have a partially or fully opened front. Openings may be created at a retail location, such as by a stacker. rear access for guide insertion

In one example, a rear section or tab on the carton may be opened or removed to permit insertion of the alignment device guide. The rear port should be at least slightly larger than the spring alignment device pusher plate to allow travel of the rear pull member through the port.

In another example, the rear of the carton may be completely removed. In another example, the carton may be shipped with a partially open rear wall so that the alignment device may be inserted without any modification to the carton.

In another example, rear flaps on a carton are opened, and the alignment device is inserted into rear of carton before the carton is placed on a shelf or display surface. If the alignment device is longer than the carton and the rear is opened, there can be sufficient room to permit extra merchandise items to be placed in the front of the carton and to push the rearmost item or items out of the carton.

In another example, the rear wall of the carton may be fully opened so that merchandise items may be pushed backward or forward. This approach permits extra merchandise items, such as a few items remaining in a previous carton, to be placed in the front of the carton. FIG. 10A is a rear perspective view of a carton or tray which may be opened in the rear. FIG. 1 OB is a rear perspective view of the carton of FIGF. 1 OA with a first tab or side flap 270 opened. The side flap is folded open after removing tape 271. FIG. IOC is a rear perspective view of the carton of FIGF. 1 OA with a first tab and second tab or side flap 272 opened and rail extensions 274 and 276 folded down. FIG. 10D is a rear perspective view of a carton or tray of FIG. 10A with merchandise items, with the rear wall closed. FIG. 10E is a rear perspective view of a carton or tray of FIG. 1 OA with merchandise items, with the rear wall open so that merchandise items can be pushed rearward in order to accommodate extra items in the front of the box. A rear access port may be opened with perforations which open the port downward, sideways, upward, side-by side or altogether. carton bottom and merchandise support rails

In one example, such as shown in FIGs. 13A-13C, cardboard merchandise support rails 404 and 406 are inserted into a carton before filling the carton with merchandise items. In another example, folded carton major flaps create a longitudinal channel, and the flaps serve as merchandise support rails. In another example, a channel is formed by crushing or scoring a portion of the carton bottom or flaps. In another example, a portion of the carton bottom is crimped to provide elevated merchandise item supports.

One function of the cardboard rails is to elevate the merchandise items so that an alignment device base may be inserted completely or substantially below merchandise items. Another function of the rails is to provide lateral retention of the guide between the rails. carton flaps

FIG. 11 A is a front perspective view of a partially folded carton blank with major flaps 266 and 268, and extended minor flaps 217 and 218. This blank can be folded as shown in FIG. 1 IB, which is a top view of the open assembled carton of FIG. 11 A. The minor flaps are typically folded so that there is a small gap between them. In an alternate example, the ends of the minor flaps can be angled so that the gap, if any is at an angle. FIG. l lC is a bottom view of the assembled carton of FIG. 11A where the minor flaps have angled ends. In this example, the major flaps are folded over the minor flaps. In this example, the major flaps have a gap between them intended to create a channel for the spring alignment device to reside in. FIGs. 11D and HE show a folded carton blank with integral rails where the bottom flaps have the same length as the rails.

In another example, the major flaps do not have a substantial gap between them for a channel and the minor flaps are normal lengths. This is one example of a substantially closed carton bottom. FIG. 11 shows an example of a carton blank being folded in a manner that provides support rails 266 and 268. In this example, the short, or minor flaps 217 and 218 are folded under the longer major flaps 266 and 268. A spacing may be created between the major flaps in order to provide a slot for the guide.

In another example, the carton is folded so that the minor flaps are folded inside of the major flaps.

In another example the minor flaps are folded inside of the major flaps and one or both minors have recesses or omissions to provide a channel for the spring alignment device.

In another example, the carton is folded so that the flaps are on the sides, front, or rear of the carton, and a solid carton bottom is provided. FIG. 1 ID is a front perspective view of a partially folded carton blank with integral rails where the minor flaps 217 and 218 have the same length as the major flaps 266 and 268. FIG. HE is a top view of the open assembled carton of FIG. 11 A. In this example, the minor flaps have the same dimension as the width of the major flaps. This permits the use of a rectangular carton blank.

FIG. 11 shows an example of a carton blank being folded in a manner that provides support rails 266 and 268. In this example, the short, or minor flaps 217 and 218 are folded under the longer major flaps 266 and 268. A spacing may be created between the major flaps in order to provide a slot for the guide.

FIG. 13A is a top perspective view of tray 252 with pre-formed rear access port 207 and front slot 203. FIG. 13B is a top perspective view of the tray of FIG. 13A with cardboard merchandise item support rail inserts 404 and 406. FIG. 13C is a cross section view of the tray of FIG. 13B. headroom

Headroom is defined as the distance between the top of merchandise items and the top of the carton. If an alignment device is inserted prior to opening the carton top, or if the top is only partially removed, then the guide should be designed to be no taller than the bottom channel, if any, plus headroom.

There is typically some space deliberately left between the top of a row of merchandise items and the top of the box. Thus, in many cases, it is possible for the pusher assembly to push the merchandise items slightly upwards as the pusher is inserted into a box or carton.

In one example, headroom is deliberately provided in cartons, and the cartons are stacked on a pallet sideways. The sideways orientation provides the stacking resistance that was previously provided by eliminating headroom.

In one example, the carton is inverted while the guide is inserted in order to minimize bottom obstruction during insertion.

In another example, the carton is turned sideways while the guide is inserted in order to minimize bottom obstruction during insertion. guide anchoring features on carton

In some examples, the guide is anchored to a bottom portion of the carton.

In one example, a retaining slot is provided in the bottom of the carton, and the guide has a corresponding anchor element to engage the slot. In one example, the retaining slot is engaged before the front of the carton reaches the guide, so that a slot is not required in the front of the carton. In other examples, the front of the guide may protrude through a slot in the front wall of the carton.

In order to support a relatively few number of different guides for different carton lengths, anchor slots may be provided at uniform distances from the front of the carton. For instance if the anchor slot on the guide is 12 inches from the front tip, all cartons would have an anchor slot 12" from the front, whether the carton is 12" or 16" long. The uniform spacing of the carton anchor slots permits one guide can be used with multiple lengths of boxes.

In another example, the guide is anchored to the front of the shelf. This permits the puller to be set at a desired length, and a common puller size can be used on various shelf depths.

In other examples, the carton includes friction enhancement elements, such as friction tape, to restrain the guide in the carton. carton preparation

In one example, portions of the carton top and rear are opened before retail display. In another example, the carton is provided with some or all of the desired openings, and is shrink-wrapped to contain merchandise.

In one example the shipper carton is used as the display carton. In another example, the display carton is shipped inside of the shipper carton and removed for display.

DESCRIPTION OF EMBODIMENT- use of carton with spring alignment device

The method of using the alignment system depends on whether the alignment device is attached to the shelf. One way to create the alignment system is to insert at least a portion of a pusher assembly through the rear opening of the display carton, push the guide or base forward through the display carton, then place the display carton and pusher assembly on the shelf.

Another way to create the alignment system is to attach a portion of the pusher assembly to a shelf, and then to slide a box over the front portion of the pusher assembly. In one example, a portion of the guide is secured to the shelf. In another example, the guide slides with respect to a shelf extension element which is secured to the shelf. In other examples, the alignment device may be placed on the shelf so that the rear wall of the shelf restricts backward movement of the alignment device as the carton is inserted onto the guide.

Example

Mechanical features or stops prevent the guide from sliding off of the shelf extension element. To load the carton, a portion of the guide is extended forward beyond the front edge of the shelf. The front tip of the guide is pushed into the rear opening of the carton, under the merchandise and above the floor of the carton. The carton and guide are then pushed backward along the shelf extension element until the guide either hits the back wall of the shelf or a stop feature on the shelf extension element, at which time the guide becomes stationary. The carton continues backward, loading onto the guide until it engages a locking feature such as front, bottom or rear anchor. The loaded carton can now be left at the back of the shelf for storage while excess product is placed in front of it. When there is no excess product, the loaded carton can be pulled to the front edge of the shelf for sale. When that carton is empty or ready for replacement, the carton is pulled forward off of the guide and the process is repeated.

DESCRIPTION OF EMBODIMENT- alignment device along carton side In this embodiment, an alignment device is positioned along the inside of a carton sidewall, and a rear pull member is substantially perpendicular to the carton side. The alignment device guide may be retained with guide anchor element(s) engaging one or more anchor slots in the carton side wall. The guide may also be retained with guide anchor element(s) engaging one or more anchor slots in the carton bottom in proximity to the inside wall. The guide may also be retained at the front or rear of the carton, such as described above.

DESCRIPTION OF EMBODIMENT- merchandise item packaging accommodates alignment device guide In this embodiment, the merchandise item packaging is adapted to facilitate guide insertion and operation. In one example, the items include bottom features, such as pedestals, that create a channel for positioning the guide. This approach can be used on heavier cans and jars, for instance, to reduce contact area and sliding friction on the carton bottom, and to eliminate most sliding friction relative to the guide.

In another example, pouches or cartons have voids which create bottom channel features. In another example, soft pouches are sufficiently compliant that thin guides can be inserted under the pouches without headroom.

DESCRIPTION OF EMBODIMENT- freezer shelf pusher element with an shelf extension element

In this embodiment, a guide and shelf extension element are provided on a freezer shelf. In one example, a portion of the rear shelf extension element is secured to a freezer rack, or retained between the freezer rack and the rear wall of the freezer shelf. In one example, the shelf extension element is snapped to a portion of a freezer wire shelf.

DESCRIPTION OF EMBODIMENT- multiple rows of items

Multiple rows of items can be aligned with multiple alignment devices, or with alignment devices having a wide rear pull plate.

DESCRIPTION OF EMBODIMENT- stacked cartons

In some embodiments, alignment may be provided for a stack of two or more cartons.

In one example, alignment devices are placed in the cartons before the cartons are placed on the shelf and stacked.

In another example, a lower level of carton(s) with alignment devices is provided by any method. Second level alignment devices may be restrained relative to the lower cartons by friction or by mechanical means by either restricting second level carton movement, or by restricting alignment device movement, such as with downward projecting tabs to engage the front and rear of the lower level container.

DESCRIPTION OF EMBODIMENT- Manual alignment mechanism

In many of the approaches described above, a manual pull element may be substituted for a spring.

One difference between a manual approach and a spring-driven device is that it is generally desirable to be able to retract or manually push back any portion of the pull element which extends past the front of the carton. These embodiments are examples of the invention and it is evident that those skilled in the art can make variations without departing from the inventive concepts, and the invention should be limited solely by the spirit and scope of the claims.

Claims

CLAIMS What is claimed is

1. A spring driven alignment system for pulling forward items in a display carton positioned on a shelf, the spring driven alignment mechanism system comprising

a shelf comprising a front portion and a rear portion;

a shipping and display carton comprising

a bottom,

a row of merchandise items,

a front portion, and

a rear portion with a rear slot or opening; and

a spring alignment mechanism positioned partially in the display carton, the alignment mechanism comprising

a guide positioned under the row of merchandise items and supported on the carton bottom, the guide comprising

a bottom,

a front end with a tip configured for insertion under merchandise items, and a rear end, and

a rear pull member comprising

a base, and

a pull plate,

a spring comprising

a first end secured to the guide in proximity to the front end of the guide, and

a coiled portion positioned between a pull plate and the rear end of the guide, such that coiled portion drives the pull plate to engage the rearmost item in the carton and forces the item toward the front of the display carton.

2. The spring alignment system of claim 1 wherein the tip further comprises a thin or bevelled leading edge to slide under product.

3. The spring alignment system of claim 1 wherein the tip further comprise a ramp or angle to lift merchandise items from the floor of the carton onto the guide.

4. The spring alignment system of claim 1 wherein the tip further comprises a spring feature to keep the leading edge of the tip on or in proximity to the carton floor as the guide is inserted into the carton.

5. The spring alignment system of claim 1 wherein the tip is lower than the bottom of the guide.

6. The spring alignment system of claim 1 wherein the tip further comprises a roller.

7. The spring alignment system of claim 1 wherein the tip further comprises a climber tip.

8. The spring alignment system of claim 1 wherein the tip is integral to the guide.

9. The spring alignment system of claim 1 wherein the tip is a separate element from the guide.

10. The spring alignment system of claim 1 wherein the guide further comprises a carton anchor.

11. The spring alignment system of claim 10 wherein the carton anchor is at least one carton bottom anchor.

12. The spring alignment system of claim 11 wherein the bottom anchor is at least one downwardly projecting prong.

13. The spring alignment system of claim 10 wherein the carton anchor is at least one carton front wall anchor.

14. The spring alignment system of claim 10 wherein the carton anchor is at least one carton rear wall anchor.

15. The spring alignment system of claim 14 wherein the rear wall anchor further comprises side wings.

16. The spring alignment system of claim 15 wherein the side wings are compliant and have a front taper.

17. The spring alignment system of claim 14 wherein the rear wall anchor further comprises a clip which engages a rear portion of the carton floor.

18. The spring alignment system of claim 10 further comprising a magnet, spring element, or friction enhancement element to provide resistance to the guide from slipping relative to the carton bottom.

19. The spring alignment system of claim 1 further comprising a shelf extension element, such that the rear end of the guide is slidable along the extension element toward the front portion of the shelf and toward the rear portion of the shelf.

20. The spring alignment system of claim 19 wherein the shelf extension element is removably secured relative to the shelf.

21. The spring alignment system of claim 20 wherein the shelf extension element is removably secured relative to the shelf with at least one element selected from the group consisting of clips, screws, bolts, snaps, pushpins inserted into shelf perforations, magnets, adhesives, and spring wedges placed between the rear of the shelf and a rear shelf wall.

22. The spring alignment system of claim 20 further comprising a shelf extension element retention bracket.

23. The spring alignment system of claim 22 wherein the shelf extension element retention bracket includes a lateral adjustment element.

24. The spring alignment system of claim 23 wherein the shelf extension element retention bracket includes a lateral pivot element.

25. The spring alignment system of claim 23 wherein the shelf extension element retention bracket includes a vertical pivot element.

26. The spring alignment system of claim 23 wherein the shelf extension element retention bracket includes a breakaway feature.

27. The spring alignment system of claim 19 wherein the shelf extension element is removably secured to a rear wall of the shelf.

28. The spring alignment system of claim 19 wherein the shelf extension element is a tether to a rear wall of the shelf or a rear portion of the shelf.

29. The spring alignment system of claim 1 wherein

the shelf is a freezer rack; and

the shelf extension element is secured to the freezer rack with a clip.

30. The spring alignment system of claim 1 further comprising a guide retention element for securing to guide to the shelf.

31. The spring alignment system of claim 30 further comprising ae guide retention bracket.

32. The spring alignment system of claim 31 wherein the guide retention bracket includes at least one of a lateral adjustment element, a lateral pivot element, a vertical pivot element, and a breakaway feature.

33. The spring alignment system of claim 1 wherein the carton bottom further comprises

folded minor flaps; and

folded major flaps above the folded minor flaps.

34. The spring alignment system of claim 1 wherein the carton bottom further comprises merchandise item support rails formed by spaced apart folded major flaps.

35. The spring alignment system of claim 1 wherein the carton bottom further comprises

folded major flaps; and

folded partial minor flaps above the folded major flaps, such that a portion of the minor flaps is omitted, thereby creating a channel for the guide.

36. The spring alignment system of claim 1 wherein the carton bottom further comprises

scoring the bottom of the box to create a channel.

37. The spring alignment system of claim 33 wherein the carton bottom further comprises

creating crimps or bend in flaps to elevate product and create a channel.

38. The spring alignment system of claim 1 wherein

the rear portion of the carton comprises a perforated section; and

the rear slot or opening of the carton is formed by opening or removing at least a portion of the perforated section.

39. The spring alignment system of claim 1 wherein

the rear portion of the carton comprises flaps, and

the rear slot or opening of the carton is formed by opening or removing the flaps.

40. The spring alignment system of claim 1 wherein

the rear slot or opening of the carton is pre-formed in the carton.

41. A method of aligning merchandise items in a display carton, the method comprising

providing a shipping and display carton comprising

a rear,

a bottom,

a row of merchandise items, and

a front portion;

providing a rear opening in the rear of the carton;

providing a spring driven alignment mechanism comprising

a bottom,

a front end,

a rear end, and

a tip,

a rear pull member comprising

a base, and

a pull plate,

a spring comprising

a coiled portion positioned between a pull plate and the rear end of the guide, such that coiled portion drives the pull plate to engage the rearmost item in the carton and forces the item toward the front of the display carton;

inserting the spring driven alignment mechanism into the carton; and

positioning the carton on a shelf.

42. The method of claim 41 further comprising securing the guide relative to the shelf.

43. The method of claim 42 wherein inserting the spring driven alignment mechanism into the carton and positioning the carton on a shelf further comprises

securing the guide relative to the shelf;

inserting the tip of the guide into the rear opening of the carton; and

pushing the carton onto the guide into so that the guide is positioned substantially under the row of merchandise items.

44. The method of claim 42 wherein inserting the spring driven alignment mechanism into the carton and positioning the carton on a shelf further comprises

inserting the tip of the guide into the rear opening of the carton;

pushing the guide into the carton so that the guide is positioned substantially under the row of merchandise items;

positioning the carton on a shelf by sliding the carton and guide rearward with respect to the shelf; and securing the guide to the shelf.

45. The method of claim 41 further comprising providing a spring driven alignment mechanism with a shelf extension element, such that the guide is slidable with respect to the shelf extension element.

46. The method of claim 45 further comprising securing the shelf extension element relative to a shelf.

47. The method of claim 46 further comprising

providing a shelf extension element mounting bracket, and

providing a shelf extension element pivot capability on the shelf extension element mounting bracket.

48. The method of claim 45 further comprising

providing a shelf extension element mounting bracket, and

providing a shelf extension element breakaway capability on the shelf extension element mounting bracket.

49. The method of claim 45 further comprising

providing a shelf extension element mounting bracket, and

providing a shelf extension element lateral adjustment capability on the shelf extension element mounting bracket.

50. The method of claim 45 wherein inserting the spring driven alignment mechanism into the carton further comprises

sliding the guide outwardly with respect to the shelf and the shelf extension element;

inserting the tip of the guide into the rear of the carton;

pushing the guide into the carton so that it is positioned substantially under the row of merchandise items; and

sliding the carton and guide rearward with respect to the shelf and the shelf extension element.

51. The method of claim 41 wherein providing a spring driven alignment mechanism further comprises providing a guide comprising a first part and a second part which slides relative to the first part.

52. The method of claim 51 wherein inserting the spring driven alignment mechanism into the carton and positioning the carton on a shelf further comprises

adjusting the length of the guide by sliding the second part with respect to the first part.

53. The method of claim 41 further comprising providing a carton anchor to secure the guide relative to the carton.

54. The method of claim 41 further comprising crimping a portion of the carton bottom to provide merchandise item supports.