Patent Publication Number: US-9834393-B2

Title: Storage system with stacking totes

Description:
This application is a divisional of U.S. patent application Ser. No. 12/981,000, filed Dec. 29, 2010, now U.S. Pat. No. 8,960,469, which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     Electronic marketplaces (e.g., Internet- or web-based marketplaces) have become legitimate alternatives to traditional “brick and mortar” retail stores. For instance, consumers may visit a merchant&#39;s website to view and/or purchase goods and services offered for sale by the merchant (and/or third party merchants). In many cases, consumers appreciate the convenience and simplicity of the shopping experience provided by electronic marketplaces. For example, a consumer may quickly browse an electronic catalog (e.g., via a web browser) and select one or more items from the catalog for purchase. Such items may be shipped directly to the consumer thereby relieving the consumer of the inconvenience of traveling to a physical store. 
     Some electronic marketplaces include large electronic catalogs of items offered for sale. Distributors that operate such marketplaces may process inventory of items in one or more facilities (e.g., warehouses, distributions centers, etc.). Some product sellers have facilities in only a relatively small number of locations. Shipping from the small number to myriad domestic and foreign locations of customers requires that many items be shipped long distances. 
     Some product sellers experience large seasonal fluctuations. For example, some retail merchants experience very high product demand during holiday seasons. These seasonal fluctuations cause spikes in facilities requirements. To meet the facilities requirements during these spikes, sellers may create and stock temporary facilities, such as a holiday fulfillment center. Such temporary facilities may, however, be expensive to equip and maintain. For example, a large amount of shelving may need to be constructed for a temporary fulfillment center. Conventional shelving may be capital intensive and labor intensive to construct, and may require significant planning, permitting, inspections, and certifications. Moreover, even where such temporary facilities can be made available, the facilities may not be in the optimal locations relative to the customer base. 
     Even after seasonal requirements have subsided for temporary facilities, temporary facilities and the associated equipment may consume a substantial amount of resources. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates one embodiment of a system for holding items that include cross coupled totes. 
         FIG. 2  is a top view illustrating one embodiment of a tote that can be used as modular elements for a shelving system. 
         FIG. 3  is a bottom view illustrating a corner of a tote having a side interlock socket and a split back interlock tail. 
         FIG. 4  is a bottom view illustrating a corner of a tote having a side interlock tail and a split front interlock socket. 
         FIG. 5  illustrates one embodiment of a system having totes that are cross coupled in the front-to-back direction and in the side-to-side direction. 
         FIG. 6  is a bottom view illustrating a side interlock connection between two adjoining totes. 
         FIG. 7  is a bottom view illustrating a corner interlock connection of four totes. 
         FIG. 8  illustrates an embodiment of one tier of a tote system including interlocking totes and removable panels. 
         FIG. 9  illustrates one embodiment of a removable panel for a tote. 
         FIG. 10  illustrates one embodiment of a handle for a tote. 
         FIG. 11  illustrates an embodiment of a tote system including a divider. 
         FIG. 12  illustrates a tote including stop elements for nesting totes. 
         FIG. 13  is a cross sectional view of two totes in a nested relationship. 
         FIGS. 14 and 15  are bottom views illustrating elements of a blind dovetail connection. 
         FIG. 16  illustrates a U-shaped coupler for cross coupling totes. 
         FIG. 17  illustrates a device for cross coupling four totes at a common intersection of the totes. 
         FIG. 18  illustrates one embodiment of a snap-in connection between stacked totes. 
         FIG. 19  illustrates operation of a materials handling facility that includes one or more inventory storage locations. 
         FIG. 20  illustrates one embodiment of holding items in stacked totes. 
         FIG. 21  illustrates one embodiment of making a shelving system with stacked totes. 
     
    
    
     While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims. The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include,” “including,” and “includes” mean including, but not limited to. 
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Various embodiments of systems and methods for storing items in totes are described. According to one embodiment, a system for holding items includes a base tier including two or more totes and one or more higher tiers stacked on the base tier. Each of the higher tiers includes one or more totes stacked on a tote of a lower tier. Totes in of the tiers are laterally cross coupled to one another. The totes include lateral openings that allow removal of items through the lateral opening while the totes are stacked in place. 
     According to one embodiment, a tote for holding items includes one or more item-holding portions, one or more coupling portions, and one or more lateral openings. The coupling portions can laterally couple the tote with at least one other tote. The lateral openings allow removal of items from the tote through the lateral openings. 
     According to one embodiment, a method of holding items includes providing one or more items in each of two or more totes. The totes include one or more lateral openings. At least two of the totes are laterally cross with one another to form a base tier of totes. Totes are stacked on the base tier totes to form at least one higher tier of totes. The totes are stacked such that the items in the totes are removable through at least one of the lateral openings. 
     According to one embodiment, a method of making a shelving system for storing items includes cross coupling two or totes to form a base tier of totes. The totes include one or more lateral openings. Totes are stacked on the totes in the base tier to form at least one higher tier of totes. The totes are stacked such items can be placed into the totes through the lateral openings. 
     As used herein, “coupled to” includes a direct connection or an indirect connection. Elements may be coupled to one another in any of various manners, including a fixed connection, pivoting connection, sliding connections, or combinations thereof. 
     As used herein, “cross coupled” means items are coupled to mutually inhibit separation of the items from one another. 
     As used herein, “interlock” includes a combination of elements, or portions thereof, that cooperate to inhibit separation of two or more component or elements from one another. In some embodiments, interlocks elements are integral to the parts being held together (for example, dovetails, grooves, lips, or protrusions). In other embodiments, interlock elements are separate parts (for example, coupling links, pins, or clips). Interlocking elements may connect in a press fit or a clearance fit. In certain embodiments, interlocking elements may snap together. 
     As used herein, “lateral” or “laterally” includes in a lateral direction or a generally horizontal direction. A lateral opening in a tote may be, for example, in the front side, back side, left side, or right side of the tote. 
     As used herein, a “pin” includes any element that can be positioned to constrain or hold another element in a desired position or orientation. Suitable pins may include straight pins, pegs, threaded bolts, unthreaded bolts, bars, plates, hooks, rods, or screws. 
     As used herein, “shelving” includes any system, element, or combination thereof that has one or more shelves, platforms, or other surfaces for holding items. 
     As used herein, a “space” means a space, area or volume. 
     As used herein, “tier” means a row or layer of one or more objects. A tier may be part of an arrangement or assembly of objects. Objects in one tier may be above or below items in one or more other tiers of objects within an arrangement. For example, a stack of totes may include a bottom tier and one or more higher tiers above the bottom tier. 
     As used herein, “tote” means a bin, crate, box, or other container in which or on which one or more items can be placed. A tote may be open on or more of its sides. In various embodiments, a tote can be used for storage, transportation, display, or environmental protection. A tote may be any shape or size. 
     In some embodiments, two or more totes are connected with one another to create shelving for holding items.  FIG. 1  illustrates one embodiment of a system for holding items that include cross coupled totes. System  100  includes totes  102  and removable walls  104 . Items such as books, CDs, or DVDs may be held in each of totes  102 . Totes  102  are stacked on one another to form columns and arranged next to one another to form rows. Totes  102  are arranged in tiers  106 A,  106 B, and  106 C. 
     Removable walls  104  physically separate contents in the front columns of totes  102  from the contents in the back columns of totes  102 . Each of totes  102  includes front opening  110  and back opening  112 . Front openings  110  and back openings  112  may allow contents in totes  102  to be removed from the totes. For example, in the arrangement shown in  FIG. 1 , front openings  110  may allow contents to be removed from the front of totes  102  on the front side of system  100 . Back openings  112  may allow contents to be removed through the back of totes  102  on the back side of system  100 . 
     In the embodiment illustrated in  FIG. 1 , system  100  is two totes wide (side to side) by two totes deep (front to back) by three totes high. Nevertheless, a shelf system may, in various embodiments, be any number of totes wide, deep, or high. In one embodiment, a shelf system is eight totes wide, two totes deep, and seven totes high. The width of a tote system may be, in one embodiment, about 16 feet. 
     Within each of tiers  106 A,  106 B, and  106 C, totes  102  may be cross coupled front-to-back and side-to-side. For example, in tier  106 C shown in  FIG. 1 , totes  102  in front columns  114  couple with the adjacent totes  102  in rear columns  116  at interlocks  118 , and totes  102  on left columns  120  couple with totes  102  on right columns  122  at interlocks  124 . 
     Although in the embodiment shown in  FIG. 1 , totes in a system are coupled in two directions (front-to-back and side-to-side), in certain embodiments, totes in a system may be cross coupled in only one direction (for example, side-to-side only, or front-to-back only). 
     Totes may be used to store any items. Examples of items that can be stored in a tote include books, CDs, DVDs, software media, jewelry, apparel (for example, men&#39;s dress shirts), shoes, hardware, office supplies, or household items. 
       FIG. 2  is a top view illustrating one embodiment of a tote that can be used as a modular element for a shelving system. Tote  140  includes bottom panel  142 , front panel  144 , back panel  146 , and side panels  148 A and  148 B. Side panels  148 A and  148 B include handles  150 . Front panel  144  includes front opening  152 . Back panel  146  includes back opening  154 . 
     Bottom panel  142  includes corrugations  155 . Corrugations  155  may increase the load bearing capacity of tote  140  and/or increase rigidity of bottom panel  142  when items are placed in tote  140 . 
     In some embodiments, a tote includes cross coupling portions. The cross coupling portions can be used, for example, to couple with other totes within a tier of a storage system. In some embodiments, coupling portions are used to interlock one tote with another. In  FIG. 2 , for example, tote  140  includes dovetail interlock elements. Side panel  148 A includes side interlock sockets  160 . Side panel  148 B includes side interlock tails  162 . Front panel  144  includes front interlock socket  166 . Front interlock socket  166  is split by front opening  152 . Back panel  146  includes back interlock tail  168 . Back interlock tail  168  is split by back opening  154 . 
       FIG. 3  is a bottom view illustrating a corner of a tote having a side interlock socket and a split back interlock tail. Tote  140  includes side interlock socket  160  and back interlock tail  168 . 
       FIG. 4  is a bottom view illustrating a corner of a tote having a side interlock tail and a split front interlock socket. Tote  140  includes side interlock tail  162  and front interlock socket  166 . 
       FIG. 5  illustrates one embodiment of a system having totes that are cross coupled in the front-to-back direction and in the side-to-side direction. Side interlock sockets  160  of totes  140  may interlock with interlock tails of an adjacent tote to cross couple side panel  148 A of totes  140  with the side of the adjacent tote. Side interlock tails  162  of totes  140  may interlock with side interlock sockets on an adjacent tote to cross couple side panel  148 B of totes  140  with the adjacent tote. 
     Front interlock socket  166  of totes  140  may interlock with a back interlock tail on an adjacent tote to couple front panel  144  of tote  140  with the back of the adjacent tote. Back interlock tail  168  of totes  140  may interlock with a front interlock socket on an adjacent tote to couple back panel  144  of tote  140  with the front of the adjacent tote. 
       FIG. 6  is a bottom view illustrating a side interlock connection between two adjoining totes. Side interlock tail  162  and side interlock socket  160  interlock to couple side panel  148 A of one of totes  140  with side panel  148 B of another one of totes  140 . 
       FIG. 7  is a bottom view illustrating a corner interlock connection of four totes. Front interlock tail  168  of one of totes  140  interlocks with back interlock tail  166  of another one of totes  140  to couple the totes front-to-back. 
     In some embodiments, totes are stackable such that one tote can be placed on top of another in a manner that maintains all or most of the storage capacity within each tote. In the embodiment shown in  FIGS. 2 and 5 , side panel  148 A of tote  140  includes central shelf  180 . Side panel  148 B of tote  140  includes corner shelves  182 . One of corner shelves  182  is provided in each corner on side panel  148 B. Central shelf  180  includes central alignment posts  184 . Corner shelves  182  include corner alignment posts  186 . 
     Tote  140  includes central pads  190  adjoining side panel  148 B and corner pads  192  adjoining side panel  148 A. As shown in  FIGS. 3, 4, and 6 , central pads  190  include central alignment sockets  194 . Corner pads  192  include corner alignment sockets  196 . 
     Totes  140  may be stacked in an alternating orientation, such that each tote is rotated in a horizontal plane 180 degrees relative to the tote it is stacked upon. Thus, when totes  140  are stacked on top of another, central pad  190  on side panel  148 B of each of totes  140  may rest on central shelf  180  on side panel  148 A of the tote immediately below. Each of corner pads  192  on side panel  148 A may rest on one of corner shelves  182  on side panel  148 B of the tote immediately below. With each additional tier, the orientation of the totes may be reversed such that, for any given tote, side panel  148 A is resting on side panel  148 B of the tote below and side panel  148 B is resting on side panel  148 A of the tote below. 
     When totes  140  are stacked on top of another, each of corner alignment sockets  196  on side panel  148 B of one tier of totes  140  may align with and receive one of corner alignment posts  186  on side panel  148 A of the tier of totes  140  immediately below it. Each of central alignment sockets  194  on side panel  148 A of the lower tier of totes  140  may align with and receive one of central alignment posts  184  on side panel  148 B of the tier of totes  140  immediately below it. Engagement of alignment sockets on alignment posts of a lower tier of totes may maintain the totes in a stacked relationship with one another. 
     In some embodiments, a tote includes one or more removable panels. Removable panels may provide protection for, and/or retain, items in a tote. Removable panels may provide lateral access to the contents of a tote.  FIG. 8  illustrates an embodiment of one tier of a tote system including interlocking totes and removable panels.  FIG. 9  illustrates one embodiment of a removable panel for a tote. In some embodiments, a removable panel may be used, for example, to fill front opening  152  or back opening  154  of tote  140  shown in  FIG. 8 . Removable panel  200  includes wall  202 , rails  204 , pins  206 , and latching tabs  208 . Wall  202  includes corrugations  210 . To install removable panel  200  in front panel  144  of tote  140 , rails  204  may be engaged in guides  212  in the sides of front opening  152 . Removable panel  200  may be advanced downwardly on slots  212  until removable panels  200  bottom out on lower lip  214  of front panel  144  shown in  FIG. 8 . Pins  206  on the leading edge of removable panel  200  may engage in sockets  216  of front panel  144 . At the same time, posts  220  at the top of rails  204  may become flush with the top of front panel  144 . Latching tabs  208  of removable panel  200  may pass through slots  218  in front panel  144  of tote  140 . Latching tabs  208  may resiliently latch in slots  218 . 
     A tote in a shelving system may have any shape and size. The dimensions may be based, for example, on the items to be stored in the totes. In one embodiment, tote  140  is at least about 12 inches in depth. In one embodiment, front opening  152  and back opening  154  are about 9.5 inches high, about 19.75 inches wide at the top of the opening, and about 17.75 inches wide at the bottom of the opening. 
     System  100  includes bin label  230 . Bin label  230  may be used as an identifier for the system of totes. Each of totes  140  may include one of tote labels  232 . Each of tote labels  232  may be used as an identifier for the particular tote on which it is placed. In certain embodiments, multiple bin identifiers may be assigned to each tote in a system of totes. In one embodiment, up to two bin identifiers can be assigned to each tote. One of the assigned bin identifiers may be placed on one side of a divider for the tote and the other assigned bin identifier can be placed on the other side of the divider. The bin identifiers can be changed manually if the location of the tote in the fulfillment center changes. In another embodiment, one of the assigned bin identifiers is placed on one side of the tote and the other assigned bin identifier is placed on another side of the tote (for example, the opposite side of the tote). 
       FIG. 10  illustrates one embodiment of a handle for a tote. Handle  150  includes grip  242 . Grip  242  includes concave edge  244 . Concave edge  244  may create an opening to allow handle  150  to be used when totes  140  are coupled with one another (such as the opening shown between totes in  FIG. 8 ). 
     In some embodiments, a tote system includes one or more dividers. The dividers may subdivide the space in a tote into two or more segments.  FIG. 11  illustrates an embodiment of a tote system including a divider. Tote system  260  includes tote  262  and divider  264 . Divider  264  may couple with tote  262  in receptacles  266 . Pins  268  may engage in holes corresponding holes in tote  262 . Divider  264  may create left and right volumes for holding items in totes  262 . In some embodiments, latching tabs on divider  264  may snap into slots in tote  262 , similar to that shown and described above for removable panels  200  relative to  FIG. 9  and  FIG. 10 . Engagement of latching tabs in the slots may serve to retain divider  264  in tote  262 . In some embodiments, a tote is dimensioned so that a common part can be used as either a divider or a removable wall. For example, both receptacles  266  and the front and rear openings of tote  262  may receive divider  264 . A system that allows a removed wall to be installed as a divider may help keep removed walls from being lost or separated from their respective totes. 
     In some embodiments, totes in a system are nestable such that one tote can be placed on top of another in a compact manner. Totes may be nested, for example, when shelving systems are not needed for storing items (for example, during non-holiday seasons). 
     In some embodiments, a tote includes stop elements. Stop elements may stop a tote being nested at a desired level. For example, stop elements may keep nested totes from becoming jammed together.  FIG. 12  illustrates a tote including stop elements. Tote  140  includes nesting overload ribs  270 . Pads of a tote nested in tote  140  may bottom out on nesting overload ribs  270 . 
       FIG. 13  is a cross sectional view of two totes in a nested relationship. The upper one of totes  140  is bottomed out on nesting overload ribs  270  of the lower one of the totes. 
     In some embodiments, totes are made to be selectively nested or stacked based on the orientation of the totes relative to one another. For example, for totes  140  shown in  FIG. 8 , when totes  140  are placed one on another such that sides  148 A are aligned with one another and sides  148 B are aligned, totes  140  may nest, for example, in the manner shown in  FIG. 13 . By contrast, when totes  140  are placed one on another such that sides  148 A and side panels  148 B alternate, totes  140  may stack, for example, in the manner shown in  FIG. 1 . 
     In some embodiments, a dovetail connection may be a blind connection.  FIGS. 14 and 15  are bottom views illustrating elements of a blind dovetail connection. Tote  280  includes blind dovetail socket  282  and reinforcing webs  284 . Tote  286  includes tail  288  and reinforcing webs  290 . Tail  288  of tote  286  may couple in blind dovetail socket  282  of tote  280 . Reinforcing webs  284  and  290  may reduce stress at the dovetail connection. 
     In the embodiments shown in  FIGS. 5, 14, and 15 , totes are cross coupled by way of dovetail connections. Totes in a shelving system may, however, be cross coupled in various embodiments by any other coupling arrangement. Examples of coupling arrangements include pin-and-socket, snap-in connections, and hooks and grooves. 
     In some embodiments, a separate coupling device is used to couple adjacent totes to one another.  FIG. 16  illustrates a U-shaped coupler for cross coupling totes. Totes  300  include rims  302 . Rims  302  include through holes  304 . Coupler  306  include cross bar  307  and pins  308 , which combine to form a U-shape. Each of pins  308  of coupler  306  may pass through one of through holes  304  in totes  302 . Protrusions  310  of pins  308  may catch on the underside of rims  302  of totes  300 . Pins  308  may snap into engagement on totes  300 . 
     In certain embodiments, separate couplers are used to supplement, or in lieu of, integral coupling portions on totes. For example, as shown in  FIGS. 3, 6, and 7 , totes  140  include holes  167 . Couplers may be inserted into various combinations of holes  167  in adjacent totes to cross couple the totes. For example, as shown in  FIG. 7 , coupler  169  may be used to cross couple adjacent totes  140 . 
     In some embodiments, totes are cross coupled at an intersection of the corners of a set of totes.  FIG. 17  illustrates a device for cross coupling four totes at a common intersection of the totes. Totes  320  include holes  322 . Coupling device  324  includes plate  326  and pins  328 . One of pins  328  of coupling device  324  may be received into each of holes  322  of totes  320 . Coupling device  324  may couple all of totes  320  to one another. 
     In some embodiments, totes in a stack may be coupled to inhibit vertical separation of the upper and lower totes. Examples of coupling arrangement include snap-in elements on dedicated fasteners such as clips or screws.  FIG. 18  illustrates one embodiment of a snap-in connection between stacked totes. The lower of totes  340  includes pin  342 . The upper of totes  340  includes socket  344 . Socket  344  includes slots  346 . Protrusions  348  may snap into slots  346 . Engagement of pins  342  of the lower one of totes  340  in socket in the upper one of totes  340  may inhibit separation of totes  340  when stacked. In some embodiments, a shelving system is coupled to inhibit separation in vertical and horizontal directions. For example, a shelving system may include horizontal cross coupling as described in  FIG. 1  and vertical cross coupling as described in  FIG. 18 . 
     In some embodiments, the pin and socket relationship between totes may be reversed from that shown in  FIG. 18  such that the pin is on the upper one of the adjoining totes and the socket is on the lower one of the adjoining totes. 
     Although the totes described above relative to  FIGS. 1-10  are depicted as having a rectangular footprint, totes for a shelving system may be, in various embodiments, any shape. Suitable shapes may include round, hexagonal, octagonal, triangular, or irregular. Different totes within a shelving system may be all the same size or different sizes. 
     In some embodiments, a tote system may include a pallet for supporting and/or transporting stacks of totes. In some embodiments, a single pallet runs the entire width and depth of a shelving system (for example, 16 feet wide by 3 feet deep). A pallet may include stiffening elements (for example stiffening ribs) and/or mounting portions for moving the system (for example, for moving the system with a forklift or crane.) 
     In some embodiments, a tote system includes a pallet with modular sections. Each modular section may support part of the totes in a shelving system. For example, in a shelving system that is 2 totes deep by 8 totes long, a pallet may include 4 pallet modular sections, each of which supports a 2 by 2 stack of totes. The modular sections of the pallet may include coupling elements for connecting the modular sections to one another. For example, the modular sections of the pallet may include dovetail elements similar to those in totes  140  described above relative to  FIG. 2 . 
     In certain embodiments, a pallet includes elements for aligning stacks of totes on the pallet. The alignment elements may be arranged to correspond to alignment elements on the totes. For example, a pallet for totes  140  shown in  FIG. 2  may include posts that correspond to alignment sockets  194  and  196  described above relative to  FIGS. 2, 3, 4, and 6 . In certain embodiments, a pallet may include elements for coupling the totes on the pallet. In one embodiment, a pallet includes elements for snapping totes in place on the pallet. 
     In some embodiments, a shelving system of totes includes lids. In some embodiments, lids are provided for totes in the uppermost tier of a system. For example, a lid  123  may be provided on each of totes  102  in tier  106 C shown in  FIG. 1 . Lids may keep unwanted materials out of a system. In some embodiments, lids on the top tier of totes in a system keep water (such as from building sprinkler system) from entering a totes in a system. 
     A tote for a shelving system, or portions thereof, may be produced by various manufacturing processes, including molding, casting, machining, extruding, forming, or cutting. In one embodiment, an air directing device is injection molded. Suitable materials for a tote may include a polymer or a metal. In certain embodiments, a tote is made of a fire-retardant polymeric material. In some embodiments, a tote is produced as a single part, such as by molding, forming, or machining. In other embodiments, an air directing device is an assembly of two or more parts. 
     In various embodiments, a shelving system including stacked totes is used for storing items in a materials handling facility. A materials handling facility may include, for example, one or more facilities that process, store, and/or distribute units of items including but not limited to warehouses, distribution centers, hubs, fulfillment centers, nodes in a supply chain network, retail establishments, shipping facilities, stock storage facilities, or any other facility configured to process units of items. 
     In some embodiments, stacked totes are used to construct shelving to create or expand capacity for inventory. The capacity may be used, for example, to quickly fulfill a temporary or transient need for additional capacity, such as during a holiday season. After the need for additional capacity has passed, the totes may be unstacked and removed from their deployed location. In one embodiment, a shelving system constructed from totes is used at a holiday fulfillment center. A holiday fulfillment center may be in a warehouse, tent, pole barn, or any other suitable building or location. After the holiday season is over, the totes may be removed and the location vacated or re-configured for a different purpose. 
       FIG. 19  illustrates a logical representation or view of the operation of one or more materials handling facilities that include one or more inventory storage locations. Some or all of the inventory storage locations may include shelving systems constructed from stacked totes, such as described above relative  FIG. 1 . In various embodiments, a fulfillment network including multiple materials handling facilities (each of which may be configured in a manner similar to that of materials handling facility  500 ) may be responsible for fulfilling multiple orders, such as orders placed through an electronic commerce (“e-commerce”) portal, such as commerce portal component  110 . 
     In various embodiments, a materials handling facility may include one or more facilities that process, store, and/or distribute units of items including but not limited to warehouses, distribution centers, hubs, fulfillment centers, nodes in a supply chain network, retail establishments, shipping facilities, stock storage facilities, or any other facility configured to process units of items. For example, this  FIG. 19  may illustrate an order fulfillment center of a product distributor, according to some embodiments. 
     Material handling facility  500  may include one or more inventory storage locations  531  that each hold inventory  530 . In one embodiment, some of inventory storage locations  531  are permanent storage locations and others of inventory storage locations are expansion locations, such a tent or pole barn for a holiday fulfillment center. The expansion locations may be outfitted with shelving systems constructed from stacked totes, such as described above relative to  FIGS. 1-10 . In certain embodiments, all of inventory storage locations  531  of a material handling facility  500  are constructed from stacked totes. 
     In some embodiments, a supplier ships inventory items (such as books and CDs) to inventory storage locations  531  with the items pre-loaded in totes. The supplier-loaded totes may be stacked at inventory storage locations  531 . In some embodiments, stacks of totes pre-loaded with inventory items are shipped (for example, on a pallet) to storage locations  531 . 
     Multiple customers  510  may submit orders to commerce portal component  110  (which may be implemented on one or more network content servers  112 ), where each order specifies one or more items from inventory  530  to be shipped to the customer that submitted the order. The customer orders may be provided to order management component  118 , which as described above may assign such orders to a materials handling facility (e.g., a fulfillment center), as illustrated as orders  520 . As described above, in various embodiments, the merchant may determine when a customer selects a substitute item for acquisition (e.g., after the customer is provided with an order status message that recommends one or more items). In these cases, commerce portal component  110  may also provide order management component  118  with substitute orders that specify any substitute items specified by the customer. The order management component may assign any of the above-described orders to a materials handling facility in order to initiate fulfillment of the orders. In the illustrated embodiments, the orders assigned to materials handling facility  500  are illustrated as orders  520 . 
     To fulfill the orders  520 , the one or more items specified in each order may be retrieved, or picked, from inventory  530  (in the materials handling facility, as indicated at  540 . In some embodiments, the items are picked from lateral openings in stacked totes, such as the totes described above relative to  FIGS. 1-10 . 
     Picked items may be delivered or conveyed, if necessary, to one or more stations in the materials handling facility for sorting  550  into their respective orders, packing  560 , and finally shipping  570  to the customers  510 . In various embodiments, picked items may be delivered to a station where individual units of items are associated with and placed into particular conveyance receptacles, which are then inducted into a conveyance mechanism. The conveyance receptacles may then be routed to particular destinations for the items contained within the receptacles in accordance with the requests (orders) currently being processed, e.g. to sorting stations, under direction of a control system (e.g., control system  502 ). A picked, packed and shipped order does not necessarily include all of the items ordered by the customer; an outgoing shipment to a customer may include only a subset of the ordered items available to ship at one time from an inventory storage location. 
     A materials handling facility may also include a receiving  580  operation for receiving shipments of stock (e.g., units of inventory items) from one or more sources (e.g., vendors) and for moving or “stowing” the received stock into stock storage (e.g., inventory  530 ). In some embodiments, items are received in totes. In some embodiments, inventory storage locations and/or shelving systems within existing inventory storage locations are expanded to accommodate shipments of stock. 
     As described above, when incoming shipments are delayed or canceled by the vendor, exceptions may occur for customer orders relying on such items. In various embodiments, the receiving  580  operation may also receive and process returned purchased or rented items or orders from customers. At least some of these items are typically returned to inventory  530 . 
     The various operations of a materials handling facility may be located in one building or facility, or alternatively may be spread or subdivided across two or more buildings or facilities. In various instances, it should be understood that references to elements, units, items, processes (or anything else) as being located within materials handling facility  500  may easily be extended to encompass elements, units, items, processes (or anything else) proximate to but not physically located within materials handling facility. For example, various elements, units, items, or processes (or anything else) may be implemented outside of the materials handling facility, according to some embodiments. 
     In various embodiments, shipments of one or more items at shipping  570  may be transferred to one or more shipment carrier network(s)  575 . Each shipment carrier&#39;s network may include one or more distribution facilities for storing items (e.g., hubs) as well as vehicles for conveying shipments (e.g., trucks) from such distribution facilities and/or materials handling facilities (such as materials handling facility  500 ) to various destinations (e.g., customer specified destinations). 
     In some embodiments, a method of storing items (for example, in the inventory of a merchant) includes holding items in stacked totes.  FIG. 20  illustrates one embodiment of holding items in stacked totes. At  500 , items are provided in totes. Totes may be filled by a merchant, supplier for the merchant, or another party. 
     At  502 , at least some of the totes least two of the totes are cross coupled with one another to form a base tier of totes. At  504 , totes are stacked on the base tier totes to form at least one higher tier. The totes may be stacked such that the items in the totes are removable through lateral openings (for example, a front opening or a back opening) in the totes. In some embodiments, the totes are stacked at a temporary inventory storage location in response to identifying a requirement to expand a merchant&#39;s or distributor&#39;s inventory storage (for example, to handle increased orders during a holiday season). 
     At  506 , the totes are transported from a first location to a second location while at least some of the items are in the totes. The first location may be, for example, a supplier facility or merchant material handling facility. Transportation may be by truck, semi trailer, air, rail, or any other shipment method. In one embodiment, stacked, cross-coupled totes with items are transported in a semi trailer. 
     The second location may be, for example, a holiday fulfillment center. At a fulfillment center, shelving system two totes deep by N totes wide (for example, 7 totes wide) may be placed on the floor of a room in the fulfillment center. In one embodiment, several shelving systems are distributed at a fulfillment center. In one embodiment, each shelving system is two totes deep with lateral access to the totes on both the front and back of the system (for example, as shown in  FIG. 1 ). In one embodiment, 4-foot wide aisles are provided between each shelving system. 
     In some embodiments, totes of a system are stacked and cross coupled to one another before being transported to the second location. In certain embodiments, pallets are used to transport the stacked and cross coupled totes while the items are in the totes. 
     At  508 , while the totes are stacked, items are removed from the totes through the lateral openings in the totes. Items may be removed, for example, in response to receiving an order from a customer (for example, as described above relative to  FIG. 19 ). 
     In certain embodiments, empty totes may be provided to a supplier of items to be stored. The supplier may load the totes with the items and ship the items to retail merchant. The retail merchant may receive the totes from the supplier and distribute the totes at a fulfillment center. 
     In an embodiment, a method of making shelving for holding items includes cross coupling and stacking totes such that items can be removed from lateral openings in the totes.  FIG. 21  illustrates one embodiment of making a shelving system with stacked totes. At  520 , two or more totes are cross coupled to form a base tier of totes. The totes may include lateral openings. In some embodiments, the shelving systems are constructed at a temporary inventory storage location in response to identifying a requirement to expand a merchant&#39;s or distributor&#39;s inventory storage (for example, to handle increased orders during a holiday season). 
     At  522 , totes are stacked on the base tier to form at least one higher tier of totes. The totes may be stacked such that items can be placed into the totes through the lateral openings. In some embodiments, lids are placed on totes of the uppermost tier of a system. 
     At  524 , items are placed into the totes. At  526 , a customer order is received for one or more items in the totes (for example, as described above relative to  FIG. 19 ). At  528 , the item is identified and removed from the tote in response to the order. 
     Although the embodiments above have been described in considerable detail, numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.