Abstract:
An apparatus and method that effects selectable width of a roller track conveyance system having multiple roller tracks with asymmetric wall heights. The system includes a clip that connects lower or mating walls of two single roller tracks together. The connected roller tracks each have their own set of rollers, which form respective dispensing surfaces. A removable divider bar, which is capable of being selectively placed into the clips between the connected roller tracks, may be placed to divide the dispensing surfaces into separate surfaces or may be selectively removed to form a larger, single dispensing surface.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
   This is a divisional patent application of U.S. patent application Ser. No. 10/141,559 filed on May 8, 2002 now U.S. Pat. No. 7,114,606. 

   RELATED APPLICATIONS 
   This application is related to pending U.S. application Ser. No. 09/915,957, filed Jul. 25, 2001. 
   Field of Endeavor 
   This invention relates to gravity fed shelving for product conveyance, such as at the retail level and, more particularly, to conjoined roller tracks for the gravity fed shelving having a selectable track width. 
   BACKGROUND 
   Roller-type gravity fed shelving is typified by the roller-type commodity stand of U.S. Pat. No. 6,089,385, and the conveyor of U.S. Pat. No. 5,048,661. Additionally, there are also the “Volume Master” (Trademark) gravity flow tracks made by Anthony Manufacturing Company, Inc., of San Fernando, Calif. Finally, the assignee of the present application also has long made its Nyla-Rol® gravity flow shelving. Particularly, rollers transversely mounted at spaced locations along one or more track members, and with their uppermost height stationed at a point above the tracks, are used to roll-convey product along the track. In a gravity-fed alignment situation, the rear of the track is higher than the front or dispensing end, and product is fed by gravity and rolls to the frontmost available position along the track. 
   Because of the various products needing conveyance, e.g., half gallon milk containers on the one hand versus smaller soft drink cans and cartons of half and half cream on the other hand, product widths vary greatly. When used in retail sales settings, e.g., convenience stores, it is important that such gravity fed roller tracks not only operate smoothly, continuously feed the product to the front without a product “hangup” on any portion along the track, and can be easily installed and cleaned but that the tracks easily accommodate the various product widths. When the product widths vary greatly, different track widths, i.e., different structural track members, are needed in the prior art to accommodate large width differences. 
   SUMMARY 
   According to an aspect, a gravity flow roller track system for transporting product containers is disclosed including a roller track having a roller tray having a bottom and first and second side supports. The first side support is comprised of a first support wall, a first extension wall, and a guide wall, with the first support wall extending substantially normal to the bottom, the first extension wall extending downwardly and outwardly from a top edge of the first support wall, and the guide wall extending substantially normal from an outside edge of the extension wall. The second side support is comprised of a second support wall and a second extension wall, with the second support wall extending substantially normal to the bottom and having a plurality of apertures therein that are configured to receive a joining clip. The second extension wall extends downwardly and outwardly from a top edge of the second support wall. Each of the first and second support walls also include a plurality of spaced recesses. A plurality of rollers having first and second ends is further included, with the first and second ends being mounted in the plurality of recesses. 
   According to another aspect, a selectable width gravity feed roller system is disclosed with a first roller tray having a plurality of rollers and first and second sides being fixedly separated, wherein the first and second sides support the rollers. The first side has a first height and the second side has a second height that is less than the first height. Also, a second roller tray is included having a plurality of rollers and first and second sides being fixedly separated, with the first and second sides supporting the rollers. The first side has a first height and the second side has a second height that is less than the first height. Finally, a joining clip is included that is operable to connect the first roller tray to the second roller tray. 
   According to yet another aspect, a clip is disclosed for joining a plurality of roller trays in a gravity feed roller system, wherein each of the roller trays comprises a side defining a plurality of apertures. The clip includes first and second sides respectively having at least one protruding tine configured to engage with respective ones of the plurality of apertures to connect two or more of the plurality of roller trays. 
   According to yet a further aspect, the clip is further disclosed to include generally vertically-oriented slots to receivably retain a removable divider bar member to selectively separate the respective roller dispensing surfaces of the plurality of roller trays. 
   According to yet another aspect, a gravity feed roller system for dispensing products is disclosed that includes a plurality of rollers, a plurality of roller trays each having first and second vertical sides supporting the rollers to form a first roller dispensing surface. The first vertical side has a first height and the second side has a second height that is less than the first height. Also included is a means for connecting at least two of the roller trays along the second sides to form a second roller dispensing surface, the second roller surface including at least two of the first roller dispensing surfaces. 
   According to still another aspect, a method providing selectable dispensing surface widths for use in a roller track system for transporting product containers is disclosed. The method includes providing first and second roller trays, each having a plurality of rollers defining respective first and second dispensing surfaces. The first and second roller trays are connected together at respective joining surfaces of the first and second trays with means for connecting the trays, wherein the joining surfaces of the first and second trays do not extend in an upward direction above the first and second dispensing surfaces defined by the plurality of rollers and a third dispensing surface is correspondingly defined from a combination of at least a portion of the first and second dispensing surfaces. A removable divider member may be selectively disposed between the first and second roller trays, where the member is operable to selectively divide the third dispensing surface. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a selectable width gravity flow roller track system constructed in accordance with the teachings of the present invention. 
       FIG. 2  is a perspective view of the partially disassembled system shown in  FIG. 1 . 
       FIG. 3  is a cross-sectional end view of a roller track frame as used in the system of  FIG. 1 . 
       FIG. 4  is a side view of the roller track illustrated in  FIG. 3 . 
       FIG. 5  is a cross-sectional end view of the roller track system of  FIG. 1 . 
       FIG. 6  is a perspective view of a joining clip used in the roller track system of  FIG. 1 . 
       FIG. 7  is a top view of the joining clip of  FIG. 4 . 
       FIG. 8  is a side view of the joining clip of  FIG. 4 . 
       FIG. 9  is a cross-sectional side view of the joining clip of  FIG. 4 . 
       FIG. 10  is a perspective view of the selectable width gravity flow roller track system of  FIG. 1  with a divider bar selectively removed to accommodate a larger product. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The presently disclosed system is a selectable width gravity feed roller track system, as shown generally by reference  2  in  FIG. 1 . While the track system  2  is generally used as a gravity feed system, meaning that the track is angled so as to allow gravity to pull conveyed products forward to a dispensing position, it is to be understood that the presently disclosed system may be employed for other types of roller conveyors including horizontal conveyors. Furthermore, while the gravity feed roller track system  2  will be described below primarily for use with product movement within refrigerated display cases used in convenience stores, refrigerators of boxed bulk food shelving at warehouse food stores and refrigerator dairy-to-retailer roller shipper/display shelves, it is to be understood that the disclosed system may be employed in other situations requiring product conveyance. Moreover, by selectable width, it is meant that the roller track system may convey products of a particular size, preferably in parallel as illustrated in  FIG. 1 , and also may convey larger products by the same system through modification, such as by removal of a divider bar, in order to convey these larger products as illustrated in  FIG. 10 , for example. 
   As shown in  FIG. 1 , the selectable width roller track system  2  includes a plurality of roller frames or trays  4  within which are mounted a plurality of rollers  6 . Each roller tray  4  has a bottom or base  8  that is substantially planar in shape. The roller tray  4  also includes first and second side edges or supports  10 ,  12  that extend vertically upward or substantially normal to the base  8 . The bottom  8  serves to support and fixedly separate the first and second supports  10 ,  12  substantially parallel to one another, but it will be appreciated by those skilled in the art that other means and arrangements such as supports at the ends of the first and second supports  10 ,  12  could be used to support and fixedly separate the supports  10 ,  12  parallel to one another. 
   As further shown in  FIG. 3 , the first and second side supports  10 ,  12  each include an extension wall  14  having an essentially identical height  16 . The first side support  10  also includes an extension wall  18 , which extends downward and outwardly from a top edge  20  of the first support wall  14 . As illustrated in  FIG. 3 , the first extension wall  18  extends away from the extension wall  14  of the first support  10  at an acute angle α. Preferably, the angle α is approximately 75 degrees, but may range from approximately 45 degrees to 85 degrees. The importance of this range of angles will be discussed further in detail. 
   As further shown in  FIG. 3 , the first support wall  10  also comprises a guide wall  22  that extends vertically from an outside edge  24  of the extension wall  18 . As shown in  FIG. 3 , the guide wall  22  extends substantially normal to the base  8  of the roller tray  4 . The guide wall  22  and the extension wall  14  are substantially parallel and offset by a distance δ, which is equal to the width of the extension wall  18 . Furthermore, as may be seen in  FIG. 3 , the first support  10  is substantially “z-shaped” in its vertical cross section. The importance of this shape will be discussed in further detail to follow. 
   The second support wall  12  also includes an extension wall  14 , as discussed previously. A second extension wall  26  extends downward and outward from a top edge  28  of the extension wall  14  of the second support wall  12 . As shown in  FIG. 3 , the second extension wall  26  extends downward at an acute angle β from the plane of extension wall  14 . Preferably, this angle β is approximately 45 degrees but may be less than or greater than this particular angle up to approximately 85 degrees. This angle, however, is selected, by taking account of the length of second extension wall  26 , to allow a spacing or gap between two roller trays  4  that are connected to one another, as will be described later. 
   Turning to  FIGS. 2 and 4 , each roller tray  4  further includes a plurality of spaced recesses  30  for journaling of the rollers  6  within the tray  4 . Each of the recesses  30  is formed in the extension walls  18  and  26  and the support walls  14  of the first and second supports  10 ,  12 . The recesses  30  are formed so as to substantially frictionally engage and retain hubs  32  of the rollers  6  located at each end of the rollers  6 , while allowing the rollers  6  to rotate freely. In order to accomplish this retention, top portions of the spaced recesses  30  are configured slightly smaller in diameter than the roller hubs  32 . 
   Referring to  FIG. 5 , it is noted that the placement of the recesses  30  within the first and second supports  10 ,  12  as well as the diameter  36  of the rollers  6  are selected such that a top edge  38  of the rollers  6  extends above the first and second extension walls  18 ,  28 . A benefit of such positioning is that a product  40 , as shown in phantom lines in  FIGS. 1 and 5 , may roll on the rollers with adequate clearance between a bottom surface  42  of the product  40  and the extension walls  18  and  28 . In concert with such clearance, the guide wall  22  ensures lateral positioning of the product  40 . Accordingly, the product  40  may remain correctly positioned on the roller track  4  as well as freely moving along the roller track  4  when positioned at a sufficient incline to ensure gravity feed of the product  40 . 
   Turning again to  FIG. 3 , it is further noted that the heights of the supports for each roller tray  4  are preferably asymmetric wherein a height  44  of the first support  10  is greater than a second height  46  of the second support  12 . Further, as may be seen in  FIG. 5 , the top edge of the rollers  6  is extended above the second height  46 , which is the height of the second support  12 , but preferably is below the height  44  of the first support  10  in order to allow the guide wall  22  to promote lateral positioning of the product  40 , as discussed previously. 
   A feature of the selectable width roller track system  2  illustrated in  FIG. 1  is the connection of at least two roller trays  4 , which may be selectably divided into two separate dispensing surfaces or converted into a single dispensing surface. In order to accomplish this selectability, the system  2  features a plurality of joining clips  48  that are configured to join to roller trays  4  as illustrated in  FIGS. 1 ,  2  and  5 . The clips  48  are provided with a plurality of protruding tines  50  that are configured to cooperate with groupings of apertures  52  defined within the extension wall  14  of the second supports  12  of each roller tray  4 . Specifically, the tines  50 , as shown in  FIG. 6 , are configured to insert into corresponding apertures in the aperture groupings  52  and affix the joining clip  48  to two roller trays  4  on first and second sides  54 ,  56  of the joining clip  48 , thereby conjoining or connecting two roller trays  4 . Preferably, each aperture grouping  52  includes a pair of apertures  58  as shown in  FIGS. 2 and 4  that correspond to a pair of tines  50  on each of the respective sides  54 ,  56  of the joining clips  48 . 
   The tines  50  of the joining clips  48  are configured preferably with an arrow shape as illustrated in  FIG. 7  and comprise a center post  60  that is connected to one of the sides  54 ,  56  of the joining clip  48 . A pair of flexible arms  62  are attached to an end portion  64  of the center post  60  and extend away therefrom at an angle thereby forming the arrow shape profile as seen in  FIG. 7 . The flexible arms  62  are configured such that they have a normal biased position. When the tines  50  are inserted into the locking apertures  58 , however, the flexible arms  62  are configured to allow movement of the arms  62  toward the center post  60 . The length of the flexible arms  62  is selected such that a gap γ exists between ends of the flexible arms and the sides  54 ,  56  of the clip  48 . Thus, when the tine  50  is fully inserted into the locking aperture  58 , the flexible arms  62  are able to return to their normal biased position thereby locking the tines  50  into the apertures  58 . It will be appreciated by those having skill in the art that the particular arrow shape of the tines  50 , which enable locking of the clip  48  to the roller tray  4 , may be formed in numerous different configurations that provide locking of protruding tines or nipples to a corresponding aperture. Additionally, the clips  48  are preferably made of an injection-molded plastic material, but may be constructed from any other suitable material. 
   Each of the joining clips  48  further comprise a top portion  66  as shown in  FIGS. 6–8  that includes at least one slot  68  defined therein, which is generally vertically oriented. The purpose for the slot  68  is to engage and receivably retain a removable, elongated divider bar member  70  that may be selectively placed in the roller track system to divide a singular large dispensing surface  72 , as is illustrated in  FIG. 10  and that can convey a large product  74 , e.g., a gallon container of milk, into a first dispensing surface  76  and second dispensing surface  78  as shown in  FIG. 1  that each can respectively convey a smaller product  40 , e.g., a half gallon or a quart of milk. It is noted that the  FIG. 1  illustrates that the first and second dispensing surfaces  76 ,  78  are substantially the same width. However, the widths of the first and second dispensing surfaces are not limited to the same width, but could also have differing widths. Additionally, it will be appreciated by those skilled in the art that the singular large dispensing surface  72  may consist of at least a combination of the first and second dispensing surfaces  76 ,  78 , as shown, or a combination of portions thereof. Moreover, it will be appreciated that the introduction of the divider bar  70  to divide the width of large dispensing surface  72 , will yield widths of the first and second dispensing surfaces whose sum width will be slightly less than the width of surface  72  due to the width of the divider bar  70 . 
   In order to engage the elongated divider bar  70  with the slots  68 , the divider bar  70  includes a plurality of tabs  80  that are configured to matingly insert into the slots  68  as illustrated in  FIG. 2 . Furthermore, these tabs  80  may be defined by a pair of cutout slots  82  formed in a bottom edge  84  of the divider bar  70 , thereby defining tab  80  as further illustrated in  FIG. 2 . In order to ensure proper seating of the divider bar  70  into the slot  68  defined in the top surface  66  of the joining clips  48 , a pair of partial slots  86  may further be formed in the top surface  66  of the joining clips  48 . Accordingly, a portion  88 , shown in  FIG. 7 , in the top surface  66  defined between the slot  68  and the respective partial slot  86  may positively engage with the cutout slots  82  defined in the bottom edge of the divider bar  70  to positively hold the bar  70  in place and prevent movement thereof. 
   Each of the plurality of joining clips  48  is further configured to have a predetermined thickness  90  that will ensure that the divider bar  70  has access to at least the slots  68  defined in the top portion  66  of the clips  48 . The predetermined thickness  90  is selected taking into account the horizontal distance λ of the second extension walls  12  of each roller tray  4  as illustrated in  FIG. 3 . As mentioned previously, the angle β is selected to further ensure that the divider bar  70  has access to the slot  68  in the top portion  66  of the joining clips  48 . As is evident, the lesser the angle α, the lesser the distance λ becomes. When two of the roller trays  4  are connected together with the joining clips  48 , a gap  92  as shown in  FIG. 5  is defined between the extension walls  26  of the two connected roller trays  4  that permits insertion of the divider bar  70  into the slots  68  of the joining clips  48 . 
   As a further feature to assist in connecting the joining clips  48  to the extension walls  14  of the second supports  12  the joining clips  48  may further include a locating lug or guidepost  94  located on each of the sides  54  and  56  of the joining clip  48  as illustrated in  FIGS. 6 and 7 . These guideposts are configured to mate with a guide aperture  96  that is part of the aperture groupings  52 . Preferably the guideposts  94  have a length greater than the length of the tines  50  such that the guideposts  94  engage with the guide apertures  96  prior to the tines  50  engaging with the locking apertures  58  during insertion. Thus, the insertion of the guideposts  94  into the guide apertures  96  ensures that the joining clips  48  are properly located in a prescribed position where the tines  50  will properly engage with the locking apertures  58 . 
   It is noted that the means used to connect two roller trays  4 , namely the joining clips  48  and associated aperture groupings  52 , is only one conceivable means of fastening two roller trays  4  together in order to effect a selectable width gravity feed roller system. It will be appreciated by those of ordinary skill in the art that other means to fasten the roller trays  4  together may be employed such as screws, nuts and bolts, soldering, welding, clips, bars, elastic bands, magnets and other conceivable fastening means in the present system in order to join two trays  4  together. Furthermore, the divider may be comprised of any suitable means that allows the larger dispensing surface  72  to be divided into the respective first and second singular dispensing surfaces  76  and  78  by locating the divider at the junction of the second supports  12  of the roller trays  4 . 
   While the present disclosure has explained particular examples, it will be apparent to those of ordinary skill in the art that the scope of this disclosure is not limited to those examples. On the contrary, this patent covers all apparatus as falling within the spirit and scope of the appended claims, either literally or under the doctrine of equivalents.