Patent Publication Number: US-7588404-B2

Title: Container handling apparatus and container

Description:
TECHNICAL FIELD 
   The present application relates to container handling devices and more particularly to a container handling device capable of pushing and pulling a container. 
   BACKGROUND 
   Palletized loads are commonly used to transport product. Typically, the product is placed on a pallet that rests on the ground and the pallet is moved from one location to another using a forklift. 
   To provide greater flexibility in palletizing, slipsheet palletizing has been proposed where a thin sheet of material is interposed between adjacent units of product that are stacked one on top of the other. To remove the top unit, a modified forklift or lift truck having a gripping device is used. The gripping device can grasp an edge of the slipsheet and pull the slipsheet including the product disposed thereon onto the forklift or lift truck. 
   While use of a forklift and palletized loads may be suitable for certain products at some stages during the distribution process such as in a large warehouse, they are not particularly well-suited to accomplish many downstream processes. For example, a large forklift is not well-suited where greater flexibility may be important such as in re-stocking store displays from an on-site storage location. Additionally, forklifts and lift trucks tend to be relatively large and may be somewhat unsuitable for use at many retail locations. 
   SUMMARY 
   In an aspect, a container handling apparatus for use in loading and transporting a container from a first location to a second location is provided. The container handling apparatus includes a mast and support structure for supporting the container thereon. The support structure is vertically positionable relative to the mast. The container handling apparatus also includes a container interlocking member including an engaging portion for use in releasably engaging a container. The container interlocking member is horizontally positionable relative to the support structure and configured to provide a pivot axis about which the container can pivot relative to the interlocking member when engaged with the container. 
   In another aspect, a container capable of being engaged by a container handling apparatus is provided. The container includes a container body including a bottom. The container body is convertible between an enclosed configuration where an interior volume is enclosed by the container body and a display configuration where first and second access openings provide access to the interior volume. The container includes device engagement structure sized and configured to receive an interlocking member of a container handling apparatus. The device engagement structure is configured to engage with the interlocking member to allow the container handling apparatus to move the container. 
   In another aspect, a method of handling a container using a container handling apparatus includes releasably engaging a container with a container interlocking member of the container handling apparatus. The container has device engagement structure that is configured to mate with the container interlocking member. The container is lifted using the container handling apparatus such that the container interlocking member provides a pivot axis about which the container pivots relative to the interlocking member. The container is located on a support member of the container handling apparatus by pulling the container in a direction toward the container handling apparatus using the interlocking member. 
   The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a front view of an end-aisle store display including containers in a display configuration; 
       FIG. 2  is a front view of an embodiment of a container handling device for a container; 
       FIG. 3  is a side view of the transport device of  FIG. 2 ; 
       FIG. 4  is a side view of an embodiment of a container manipulation device; 
       FIG. 5  is a top view of the container manipulation device of  FIG. 4 ; 
       FIG. 6  is a top view of an embodiment of an interlocking member; 
       FIG. 7  is a side view of the interlocking member of  FIG. 6 ; 
       FIG. 8  is a prospective view of an embodiment of a container suitable for use with the transport device of  FIG. 2  in an enclosed configuration; 
       FIG. 9  is a detail view of an embodiment of a device engagement structure; 
       FIG. 10  is a side, section view of the device engagement structure of  FIG. 9  along line  10 - 10 ; 
       FIG. 11  is a side, section view of the device engagement structure along line  11 - 11  of  FIG. 9  engaged with the interlocking member of  FIG. 6 ; 
       FIG. 12  is a detail view of another embodiment of a device engagement structure; 
       FIG. 13  is a top, partial view of another embodiment of an interlocking member; 
       FIG. 14  is a top, partial view of another embodiment of an interlocking member; 
       FIG. 15  is a perspective view of an embodiment of an aisle display; 
       FIG. 16  is a front view of an embodiment of a display; 
       FIG. 17  is a side view of an embodiment of an one-sided display; 
       FIG. 18  is a side view of an embodiment of a two-sided display; 
       FIGS. 19A through 19J  show one embodiment of method of restocking a display using the transport device of  FIG. 2  and the container of  FIG. 8 ; 
       FIGS. 20A through 20J  show one embodiment of a method of restocking a display using the transport device of  FIG. 2  and the container of  FIG. 8 ; and 
       FIG. 21  is a detail view showing the container of  FIG. 8  raised off a support structure using the handling device of  FIG. 2 . 
   

   DETAILED DESCRIPTION 
   Referring to  FIG. 1 , an end-aisle store display  2  is disposed between aisles  3  and  5 . The store display  2  includes multiple, display-ready containers  50  placed upon shelves  4  of the display  2 . Each container  50  has a prepackaged amount of product  6  disposed therein and is capable of displaying the product  6  for customer viewing and purchase. While most of the containers  50  are illustrated as being at least partially filled with product  6 , container  50 ′ is empty because all of the product  6  disposed therein has been removed. A container handling apparatus  10  is used to transport a filled container  50 ″ from a storage location (not shown) to the display  2 . The handling apparatus  10  can, itself, locate the container  50 ″ both vertically by lifting the container  50 ″ and horizontally by pushing the container  50 ″ to facilitate positioning of the container  50 ″ on the display  2 . The handling apparatus  10  can also remove a container  50  from the shelf  4  by pulling the container  50  therefrom. 
   Referring to  FIG. 2 , the handling apparatus  10  includes a mast  12  and a base  14  connected to the mast  12 . The base  14  can include, for example, a battery (not shown) and/or other components for automating aspects of the handling apparatus. The mast  12  may include multiple stages (not shown) where a first stage moves relative to a second stage. The stages may or may not be nesting. A handle  16  is also connected to the mast  12  and can facilitate user control of the handling apparatus  10 . A container manipulation device  18  is provided that is vertically and horizontally positionable relative to the mast  12 . 
   In some embodiments, wheels  40  may be driven by a motor (e.g., an electric motor connected to a power source, such as a battery). In some instances, the handling apparatus  10  is moved manually under the power of a user with the user walking behind the handling apparatus  10 . In some embodiments, the handling apparatus  10  includes a controller (not shown) that allows the user to control movement of the container manipulation device  18  and/or wheel rotation in cases where the handling apparatus  10  is motorized. 
   Referring also to  FIG. 3 , the container manipulation device  18  can lift, lower, push and pull a container during a load/unload operation. In particular, container manipulation device  18  includes a support member  20  that forms a planar support surface  22  upon which a container can rest and a container interlocking member  24  that can engage a container to pull the container along the support surface  22 . The support member  20  is moveable in a vertical direction  31  relative to the mast for vertically positioning a container at a desired elevation. The interlocking member  24  is carried by the support member  20  and is moveable in a horizontal direction  32  relative to both the mast  12  and the support member  22  for horizontally positioning a container at a desired location. 
   The support member  20  can be formed of any suitable material including metal, plastic, low friction materials, such as nylon, polytetrafluoroethylene (PTFE), etc. A low friction coating such as Teflon® or Formica® may be applied to the support member  20  to form a low friction support surface  22 . In some embodiments, the support member  20  may include a dynamic support (e.g., an array of rollers, balls, etc.) upon which an article can rest. By dynamic support, we refer to a support capable of interacting with a load supported thereon to actively facilitate movement of the load relative to a reference, such as mast  12 . Use of low friction or dynamic supports can be particularly advantageous where relatively heavy loads are moved (e.g., 100 pounds or more). Examples of various dynamic supports can be found in pending U.S. patent application Ser. No. 11/076,016, entitled “Storage System and Method,” filed Mar. 9, 2005, the details of which is incorporated by reference as if fully set forth herein. 
   A container guard  30  includes a central mesh portion  33 , e.g., formed of metal, netting or plastic wire, however, other configurations are possible, such as a solid portion rather than a mesh portion. The solid portion could be formed of a transparent material, e.g., to allow a user to see through the container guard  30  while moving a container. The container guard  30  can inhibit spilling of articles from the container when the container is being transported and can serve as a pushing element for applying a pushing force to the container. 
   Referring also to  FIG. 4 , a mover  34  carries each of the engaging member  26  and the container guard  30 . As can be seen most clearly by  FIG. 5 , the mover  34  rides along the support surface  22  in a track  36  carried by the support member  22 . The track  36  extends substantially linearly between a front edge  37  of the support member  20  relatively far from the mast  12  and an opposite rear edge  39  of the support member  20  relatively near to the mast  12 . While a linear track  36  is illustrated, the track may not be linear. Additionally, other arrangements may be utilized to move the interlocking member  24  and the container guard  30 . For example, the interlocking member  24  and container guard may be capable of independent movement. The mover  34  may ride along a guide rail. In some embodiments, the interlocking member  24  and/or container guard  30  may not contact or ride along the support member  20  as one or both move horizontally. Instead, the interlocking member  24  and/or container guard  30  may overhang the support surface  22  and be carried, for example, by a mechanical linkage configured to extend and retract the interlocking member  24  and/or container guard  30 . 
   Referring to  FIG. 6 , the interlocking member  24  includes engaging member  26  disposed at a free end of the interlocking member  24  and a connecting member  38  connecting the interlocking member  24  and the mover  34 . Referring also to  FIG. 7 , the engaging member  26  and connecting member  38  form a substantially T-shaped projection extending integrally from the mover  34  having opposite free ends  83 ,  85  located at either side of the connecting member  38 . While  FIGS. 6 and 7  illustrate a substantially T-shaped interlocking member  24 , other configurations are possible such as a substantially L-shaped interlocking member, a substantially U-shaped interlocking member, etc. 
   Any suitable method or device can be used to move the support member  20  and the interlocking member  24 . In one embodiment, one or more electric motors (not shown) are used to move the support member  20  vertically and the mover  34  horizontally. The motor may be connected to a power source, such as a battery (not shown) and may or may not be located in the base  14 . A transmission belt, chain or other mechanical connection  23  ( FIG. 5 ) can be used to connect the motor to the support member  20  and/or mover  34 . Air and/or hydraulic cylinders (not shown) may be used to move the support member  20  vertically and/or the interlocking member  24  horizontally. The cylinders may be rodless. The air or hydraulic cylinder may be connected directly to the container manipulation device  18 , or it may be mechanically connected using a linkage. 
   Referring now to  FIG. 8 , an example of a container  50  suitable for use with handling apparatus  10  includes a top wall  52 , a bottom wall  54  and side walls  56  extending between the top and bottom walls. Container  50  is convertible between an enclosed configuration where an interior volume is fully enclosed by a front wall  58 , a top wall  52 , a rear wall  60 , bottom wall  54  and end walls  62  and  64 , a display configuration where the front wall  58  and top wall  52  are moved relative to the bottom wall about joints A and B to provide side and top access openings  28  and  26 , and a collapsed configuration where each of the walls  52 ,  54 ,  58 ,  60 ,  62  and  64  are moved about their respective joints A-E to stack on the bottom wall. Configurable display containers are described in greater detail in U.S. patent application Ser. No. 11/089,523, entitled “Configurable Display Container,” filed the same day as the instant application, the details of which are incorporated by reference as if fully set forth herein. In some embodiments, container  50  has only one or more of an enclosed, display and collapsed configuration. 
   Container  50  includes device engagement structure  68  located at the bottom wall  54  that is capable of engagement with interlocking member  24 . Engagement between the device engagement structure  68  and the interlocking member  24  enables the handling apparatus  10  to pull the container  50  onto the support structure  20  and to lift the container of an underlying surface, such as a shelf. 
   Referring to  FIG. 9 , the device engagement structure  68  of the container  50  is a recess  80  that is sized and configured to receive the engaging member  26 . In the illustrated embodiment, the recess  80  extends inwardly from a surface of the bottom wall  54 , however, other configurations are possible, such as forming the recess  80  to extend inwardly from an outer surface of one or more of the side walls  56 . The recess  80  is contoured to form a notch portion  82  that is disposed between two side portions  81  and  83 . 
   Referring to  FIG. 10 , the side portions  81  include an inwardly facing, U-shaped receiving portion  84  disposed on opposite sides of the notch portion  82 . U-shaped receiving portions  84  include a lower surface  95 , a side surface  89  and a top surface  91 . Notch portion  82  provides a clearance C between the lower surface  95  and upper notch surface  93 . 
   Referring now to  FIG. 11 , notch portion  82  allows the interlocking member  24  to move vertically with the engaging member  26  disposed within the recess  80 . As shown by the dotted lines, interlocking member  26  is located beneath the U-shaped receiving portion  84  when initially disposed within recess  80 . Once the engaging member  26  is located behind the U-shaped receiving portion  84  by extending the interlocking member  24 , the interlocking member  24  can be moved vertically by raising the support member  20  such that the notch portion  82  receives the connecting member  38  of the interlocking member  24 . This vertical motion of the interlocking member  26  can place the engaging member  26  at an entrance  87  to the U-shaped receiving portion  84 . Retracting interlocking member  24  locates engaging member  26  within the U-shaped receiving portion  84 . Additional retraction of the interlocking member  24  engages the engaging portion  26  with the side surface  89  of the U-shaped receiving portion  84  and pulls container  50  in a direction toward the handling apparatus  10 . Similarly, additional vertical motion of the interlocking member  24  engages the engaging portion  26  with top surface  91  of the U-shaped receiving portion  84  and lifts at least a portion of the container  50 . 
   Referring still to  FIG. 11 , once located within the U-shaped receiving portion  84 , the engaging member  24  forms a pivot axis P about which the container  50  can pivot in the direction of arrow  86 . This can be desirable when lifting an edge of the container  50  off of a support surface on which it rests prior to or while pulling the container  50  toward the handling apparatus  10 . By providing P, relatively little torque is applied to the engaging structure  24  and the device engagement structure  68  of the container  50 . This can be particularly advantageous when loading or unloading a relatively heavy load. 
   In an alternative embodiment as shown by  FIG. 12 , the container engagement structure  90  is contoured to include a first notch portion  92  and a second notch portion  94  disposed on opposite sides of a U-shaped portion  84 . Container engagement structure can be sized and configured to receive U-shaped interlocking member  96  such as that shown by  FIG. 13  or an L-shaped interlocking member  98  such as that shown by  FIG. 14 . In other embodiments, the container engagement structure has only a single notch portion, more than two notch portions and/or more than two U-shaped receiving portions. In some instances, the receiving portion  84  may not be U-shaped. In these instances, the receiving portion may only include a side surface  89  and a top surface  91 , but not a lower surface  95  ( FIG. 10 ). 
   The above-described container  50  and handling apparatus  10  can be used at any desired type of facility including club stores, warehouses, retail stores, etc. For example, in the illustrated embodiments, handling apparatus  10  and container  50  may be used at a grocery store where product is stored at a storage location that is removed from a retail location. In this instance, it may be desirable to fill container  50  with “fast moving” items, such as eggs, for example, at a production facility. By “fast moving” items, we mean that relatively small percentage of items that drive a relatively large percentage of product movement from the storage location to the retail location for consumer purchase. Examples of fast moving items include, for example, sale items at certain price points, certain baked goods such as muffins, bagged produce such as bags of potatoes and bags of onions and certain granular products such as corn meal and flower. 
   By using handling apparatus  10  and container  50 , a user can move more product to the shelf than could be done manually in a single run. It may be desirable to fill container  50  with items (e.g., promotional and seasonal items) at a regional distribution or consolidation center. Container  10 ,  60  may also be well-suited for handling bagged products such as cat litter, pet food, sugar, etc. by providing additional protection against bag rupture as the product is being placed on a display for purchase. 
   Referring now to  FIG. 15-19 , the above-described container  50  and handling apparatus  10  can be used in conjunction with in-store displays.  FIG. 15  illustrates an example of a aisle display  100  that includes two containers  50   a  and  50   b . Container  50   a  rests on an upper shelf  102  (e.g., between about three feet and about five feet, such as about four feet from the ground) that allows for placement of the container  50   a  the customer&#39;s eye level. Container  50   b  is rests on a lower shelf  104  that is spaced from the ground (e.g., between about one foot to about three feet, such as about two feet), for example, to reduce the amount of bending a customer must do to reach an item supported on the lower shelf  104 . The aisle display  100  includes a base  108  and wheels  114  that allow for re-positioning of the aisle displays, e.g., in the store. In some instances, the aisle display  100  may accept signage  111  or graphics that can convey a brand or “Great Price!” message. The aisle display  100  can be used, for example, to reinforce value pricing to price-sensitive shoppers and/or to place supplemental inventory in aisles  113  in support of promotional pricing. 
   Referring now to  FIGS. 16 and 17 , a single-sided display  120  includes multiple containers  50  resting on shelves  122 . Display  120  may be suitable as an end-aisle display or as a seasonal display. Display  120  includes an uppermost, backstock level  124  that can be used to restock a lower level once all product is moved from a particular container  50  placing a replacement container  50  full of product within relatively close proximity to an empty container  50 . Once all product is removed from a particular container  50 , the container  50  can be placed in the collapsed configuration as previously described and removed from the display  120 . A replacement container  50  can be removed from the backstock level  124  and placed at the empty container&#39;s location on the display  120 . 
   Referring to  FIG. 18 , as an alternative to single-sided display  120 , a two-sided display  130  includes a front side  132  and a back side  134 , each of the sides  132  and  134  including containers  50 . The two-sided display may be suitable for, e.g., soft drinks, bottled water, bagged potatoes and/or onions. It can be used across adjacent aisles or in open spaces within a store. 
   Where containers  50  are used with in-store displays, such as those described above, it may be desirable to size the container  10 ,  60  to achieve a desirable viewing position for product within the container  10 ,  60 . Additionally, in some embodiments, the containers  50  are black in color, which can minimize the presence of the containers  50  to consumers, which can emphasize the product. Alternatively, the containers  50  may be any other suitable color such as red, white, blue, green, yellow, or any combination of the primary colors. In some instances, it may be desirable to match the container  50  color with a store display color or for consistency with colors associated with a particular holiday, such as Christmas, Valentine&#39;s Day, Easter, Halloween, Thanksgiving, etc. 
   Referring now to  FIGS. 19A through 19J  and  FIGS. 20A through 20J  a method  140  of container  50  handling, e.g., at a store location using the handling apparatus  10  is provided. The method  140  may be suitable to restock a store display, such as the display  2  of  FIG. 1  and display  100  of  FIG. 15 . Referring to  FIGS. 19A through 19J , the method includes a user  145  approaching a pallet  142  of stacked containers  50  at step  144 . Containers  50  forming the palletized unit  142  may have been filled at an off-site location, such as at a production facility or at a warehouse, or the containers may have been filled on-site at a retail store location. 
   A side access opening  69  is provided to the container  50  that is to be transported from the pallet  142 . As described above, the side access opening  69  is provided by pivoting front wall  58  at joint A relative to bottom wall  54 . At step  146 , the user  145  retrieves the handling apparatus  10  and approaches the pallet  142  of stacked containers  50 . At a positioning steps  148  and  150 , the container manipulation device  18  is raised vertically to align the interlocking member  24  with the device engagement structure  68  ( FIGS. 9 and 10 ) of the container  50 . The interlocking device  24  is moved horizontally to locate the engagement member  26  within the recess  80  and behind the entrance  87  to the U-shaped receiving portion  84  (see  FIG. 10 ). At step  152 , engaging member  26  is placed within the U-shaped receiving portion  84  and the container  50  is lifted to raise an edge  155  of the container off its underlying support surface  154  ( FIG. 21 ). As the container  50  is lifted, the container  50  pivots about the engagement member  26  as described above with reference to  FIG. 10 . At removal steps  156 - 160 , interlocking member  24  is retracted and the container  50  is pulled and positioned onto support member  20  with the interlocking member  24  still engaged with device engagement structure  68 . At step  162 , the container  50  is lowered for travel from the pallet  142  to a single-sided store display  120  at step  164 . At this point, it should be noted that with the container  50  engaged with the interlocking member  24 , the container guard  30  inhibits spilling of product from the container  50  by providing a temporary front wall barrier with front wall  58  of the container  50  repositioned at step  144 . Additionally, by providing an at least somewhat transparent container guard  30 , the user  145  can view the container  50  during the unload operation (see, e.g., step  148 ). In some embodiments, guides (not shown) such as markings on the container  50  and the handling apparatus  10  may be provided that aid the user in aligning the interlocking member  24  with the device engagement structure  68  of the container  50 . 
   Referring now to  FIGS. 20A through 20J , at step  166 , the container  50  while still engaged with the interlocking member  24  is placed in its display configuration as described above by moving the top  52  and front  58  walls at joint B. At steps  168  and  170 , an empty container  50 ′ is broken-down by placing the container  50 ′ in its collapsed configuration as described above. At step  172 , the container  50  is moved vertically using the container manipulation device  18  to align the container with shelf  174  of the single-sided store display  120 . At pushing steps  176  and  178 , the container  50  is pushed along the support surface  22  and onto the shelf  174 . The edge  155  of the container  50  is lowered onto the shelf  174  and the engaging member  26  is removed from the U-shaped receiving portion  84  at step  180 . Other methods of container handling are described in pending U.S. patent application Ser. No. 11/089,424, entitled “Method for Product Handling Using a Display Configurable Container,” filed the same day as the instant application, the content of which is hereby incorporated by reference as if fully set forth herein. 
   As noted above, the device engagement structure  68  of the container  50  extends inwardly from a periphery of the bottom wall  54 . This allows for exposure of the device engagement structure  68  when the container  50  is in the collapsed configuration. At step  182 , the user  145  can engage a stack  184  of collapsed containers  50  and place the stack  184  atop collapsed container  50 ′ at steps  186  and  188 . The user  145  can then engage the stack  184  including collapsed container  50 ′ to transport the stack, for example, to a location for a washing operation where the containers can be washed and then reused and/or sent to a manufacturer or warehouse for refilling. 
   A number of detailed embodiments have been described. Nevertheless, it will be understood that various modifications may be made. For example, the containers  50  may include pallet structures, e.g., at the bottom of the containers that allow a handling apparatus, such as a forklift, to engage an underside of the container to lift the container from a shelf or off the ground. Additionally, the containers  50  may include stacking structures, such as ribs extend from the underside of the containers and mating grooves formed in the tops of the containers. The stacking structures can provided added stability when the containers are stacked one on top of the other. Accordingly, other embodiments are within the scope of the following claims.