Patent Publication Number: US-7905364-B2

Title: Product display system, method and apparatus

Description:
RELATED APPLICATION 
     This application claims the priority of U.S. provisional application Ser. No. 60/942,428 filed on Jun. 6, 2007. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to retail merchandise display, and, in particular, to devices that better display merchandise to customers by moving hanging items in a display towards the front end of a rod hook as some of the items are removed from the front end of the rod hook by customers for examination or purchase. 
     BACKGROUND OF THE INVENTION 
     In the field of retail merchandising, hooks or rods are often used to present products in an accessible and space-efficient manner. These retail displays typically consist of a board that is affixed to the wall or some other stationary surface of a store with a long, straight hook extending away from the wall towards customers. A number of products, usually all identical, are then hung on the hook, as is well known. To facilitate hanging, the packaging of merchandise intended for display by hanging often includes a hole located near the top of the package. 
     One problem associated with hook and board merchandise displays is the decrease in sales due to decreasing visibility of remaining merchandise items after the front packages have been removed from a hook. This lack of visibility stems from the fact that as items are removed by customers from the end of a hook, the remaining packages near the back end of the hook are often partially hidden from view. 
     In order to overcome such problems, stores frequently employ people that go through the store at the end of the day and move merchandise items displayed on a hook towards the front end of the hook (towards customers) after customers have removed items from the front end of the hook for purchase or examination. 
     Examples of mechanical product pushers currently known include that described in U.S. Pat. No. 5,222,608, which includes a push plate mounted on the hook, as well as a compression spring which wraps around the hook and sits in vertical orientation to the plate and the wall. The compression spring is provided to apply a force forward against the plate, thereby pushing products forward. This product is disadvantageous in that it is inefficiently constructed, unattractive and may be susceptible to breakage when products are pulled off the rod hook by customers. 
     Other systems, such as that described in U.S. Pat. No. 5,114,021, have an elongated spring that extends over the hook length and draws the packages on the hook to the front. In addition to being unattractive, the spring operation is complicated mechanically, and vulnerable to damage or malfunction. Also, the spring arrangement makes a rod hook that is wider than the conventional small circular hole used in most packages designed for hanging display. 
     SUMMARY OF THE INVENTION 
     It is accordingly an object of the present invention to provide an apparatus and method for maintaining products in a hanging display at the front of their display that does not have the drawbacks of the prior art. 
     An object of the present invention is to maintain packaged items in a neat and organized manner by uniformly displaying all products at the front of the display hooks and eliminating any spaces in-between items. 
     Another object of the package display apparatus of the present invention is to provide a more attractive system that is less susceptible to tampering or damage than any preexisting product pushers, by components contained in an outer housing and thereby hidden from view. 
     In accordance with an aspect of the present invention, a display apparatus comprises an elongate support member configured to support a plurality of packaged products thereon. The support member has a proximal end secured to a fixed display surface and extending generally horizontally and forwardly therefrom, and a distal end. A product pusher device is movably supported on the support member for forward and rearward movement therealong. The product pusher device has a biasing mechanism therein that engages the support member and applies a relative force thereto from the pusher device such that the product pusher device engages a rearmost one of the plurality of packaged products and applies a pushing force thereto so as to move the packaged products forward towards the distal end of the support member. The biasing mechanism is completely supported in the product pusher device and moves therewith on the support member. 
     In an aspect of the invention, the biasing mechanism may comprise a wheel rotatably supported in the product pusher device so as to engage with the support member and to rotate when the product pusher device moves along the support member, and a biasing element supported in the product pusher device. The biasing element is connected with the wheel so as to urge said wheel to rotate so as to move the pusher device forward relative to the support member. The biasing element preferably comprises a spring having an outer end thereof fixedly connected with a housing of the pusher device, and an inner end thereof fixedly connected with the wheel so that the spring is charged when the pusher device is moved rearward and the spring urges the wheel to rotate to move the pusher device forward on the support member. 
     In another aspect of the invention, a product pushing device is configured to be supported on a rod structure. The pushing device comprises a housing configured to have the rod structure extend therethrough, and a wheel rotatably supported in the housing in a position such that the wheel is in constant engagement with the rod structure when the rod structure extends through the housing. A force generating element is supported in the housing and connected with the wheel so as to urge the wheel to rotate in a direction. 
     In still another aspect of the invention, a method for displaying products configured for hanging display comprises providing an elongate member configured to support the products hanging thereon. The elongate member has a proximal end fixedly supported on a back wall of the display and a forwardly projecting distal end having a structure configured to provide a resistance to products sliding off said elongate member. The method also includes providing a pusher device supported on the elongate member. The pusher device has a housing rotatably supporting a wheel in constant engagement with the elongate member and a coil spring connected with the wheel so as to apply a rotational force to the wheel that causes the wheel to roll along the elongate member in a forward direction towards the distal end of the elongate member. The coil spring is charged when the pusher device is pushed back on the elongate member away from the distal end. The method also includes pushing the pusher device on the elongate member back away from the distal end and loading the products onto the elongate member between the pusher device and the distal end. The rotational force applied to the wheel by the coil spring of the pusher device is selected such that the wheel moves the pusher device forward and engages a rearmost of the products and pushes all of the products on the elongate member forward until a foremost of the products engages the structure of the distal end that provides the resistance, and such that the pusher device does not impart a force to said foremost product sufficient to overcome the resistance of the distal end and push the foremost product off the elongate member. 
     According to other preferred aspects of the apparatus or method of the invention, the wheel and the support rod or member both have friction enhancing surfaces where they engage each other, especially preferably coacting gear teeth. 
     According to another aspect of the invention, a prior art display may be modified or retrofit to better operate with the method or apparatuses of the invention by applying to it a sleeve that has wheel engagement surface, e.g., gear-like teeth thereon. 
     Other objects and advantages of the invention herein will become apparent in the specification below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an embodiment of the present invention. 
         FIG. 2  is a side view of an embodiment of the present invention as it might be initially stocked with packaged retail items. 
         FIG. 3  is a side view of an embodiment of the invention after all but one of the packaged retail items have been removed. 
         FIG. 4  is a plan view of  FIG. 2 . 
         FIG. 5  is a detail sectional view along line  5 - 5  of  FIG. 4 . 
         FIG. 6  is a view as in  FIG. 5  with most of the housing cut away to show the inner workings of the pusher device. 
         FIG. 7  is a side view of an embodiment of the present invention from outside the outer housing of the pusher device. 
         FIG. 8  is a detail section view along line  8 - 8  of  FIG. 6 . 
         FIG. 9  is a detail section view along line  9 - 9  of  FIG. 6 . 
         FIG. 10  is an exploded partially cut-away perspective view of the preferred embodiment of the present invention. 
         FIG. 11  is a perspective view of an alternate embodiment of the present invention. 
         FIG. 12  is a cross-sectional elevational view of an embodiment of a retrofit system of the invention. 
         FIG. 13A  is a perspective view of the outer sleeve of the retrofit apparatus of the present invention. 
         FIG. 13B  is a detail perspective view of an alternate embodiment of the outer sleeve of a retrofit apparatus. 
         FIG. 14  is a cross-sectional view of an embodiment of a retrofit apparatus of the present invention. 
         FIG. 15  is a cross-sectional view of a hinged outer housing which can be used in the present invention. 
         FIG. 16  is an elevational view of the cross-section of the embodiment of the present invention in which the wheel is rubber. 
         FIG. 17  is an exploded perspective view of an embodiment of the present invention with a simplified two piece housing design. 
         FIG. 18  is a cross sectional view as in  FIG. 6  showing the inner workings of a pusher device of an alternate embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As best seen in  FIGS. 1 ,  2  and  4 , a product pushing device  13  is positioned along the length of an elongate support member, hook or rod  11  that supports various packaged products  15 . The packaged products  15  are typically suspended from the rod  11  from a hole  17  located near the top and in the center of the packaging  15 . The rod  11  is secured by a mounting structure  10  on its proximal end  11   b  to and protrudes generally horizontally from a back display wall or pegboard panel  19 . The front end  11   a  of the rod  11  distal from the panel  19  is bent upwards to provide a resistance to prevent the packaged products from slipping forward and falling off the rod  11 . 
     As consumers remove packaged products from the front end  11   a  of the rod  11 , the product pushing device  13  moves the remaining packages of merchandise items  15  in a forward direction, i.e., from the end of the rod secured to the wall  11   b  to the front distal end of the rod  11 , by applying a pushing force on the rear face of the last product  23 , i.e., the product that is closest rearward to the wall or pegboard  19 . However, because the entire length of the rod has been loaded with suspended products  15 , the pushing device  13  is positioned at the back end  11   b  of the rod  11 . 
     The pushing force of the pusher device  13  is such that the packages  15  on the rod are pushed forward to the distal end of the rod  11  progressively and continuously as packages  15  are removed from the end of the rod  11   a.    
       FIG. 3  shows a side view of an embodiment of the invention after all but one of the packaged retail items  23  has been removed from the front end  11   a  of the rod  11 . In this scenario, the pushing device  13  has continually moved forward as packages have been removed from the end of the rod  11   a , and is now located at the front end of the rod  11   a . As a result, although four other packages in front have been removed and only one package  23  remains hanging from the rod  11 , the package  23  is positioned on the front end of the rod  11   a . Although the pusher may continue to apply a forward pushing force on the rear face of the package  23 , both the pusher  13  and the package  23  remain on the rod due to the upward configuration at the front of the rod  11   a , which prevents articles from falling off the rod and the fact that the force that is applied by pusher  13  is not great enough to push the package product  23  over the resistance of the upwardly extending end structure  11   a  of the rod  11 . In addition, the pusher  13  has a limit of travel on the rod forward due to the teeth of its engagement mechanism with the rod  11 , in that the pusher cannot move forward beyond the teeth on rod  11 , which also prevents the pusher from pushing the last package  23  off the end of the rod  11 . 
       FIG. 5  shows a front view of the pusher unit  13 . This is the face of the pusher  13  that contacts the rearmost package on the rod  11 . The pusher is assembled from a housing  27  through which rod  11  extends, passing through openings  29 . Housing  27  includes a top plate  31  that covers the passage through which the rod  11  extends. Top plate  31  has a portion that rests on the rod  11  and may be provided with friction reducing material, e.g., Teflon™ or mechanical friction reducing systems to reduce drag as the pusher unit  13  moves reciprocally along the rod  11 . 
     As shown in the detailed elevational view of  FIG. 6  and the cross-sectional view of  FIG. 8 , a wheel  61  is rotatably supported in housing  27  so as to maintain constant engagement with the rod  11 . This wheel is preferably a standard commercially available gear wheel having gear teeth, sometimes referred to as a spur gear. The structure of the housing is such that the distance between the axis of rotation of the wheel  61  and the top of the rod  11  remains constant as the pusher device moves along the rod  11 . 
     A center rotational shaft or pin  69  is fixedly mounted with and extends from the center of the wheel  61 , so that the pin  69  rotates with the wheel  61 . The pin  69  further extends through the center of a biasing element or force generating element  65 . The element  65  is preferably a spring mechanism comprising a coil spring  33  secured in the housing  27  by an outer end, e.g., a radially projecting tongue  67  of the spring fixedly secured in a slot in the housing communicating with the spring space in the housing. The inner end of the spring  33  is fixedly attached to the shaft  69  of the wheel  61  by inserting a connection portion of the spring, such as a radially inward extending tongue  35  at the inner end thereof, into a slot in the shaft  69 . Rotation of the shaft  69  causes the coil spring  33  to tighten or release, depending on the direction of the rotation. 
     Alternatively, the force generating element  65  comprises a coil spring assembly having an outer casing that is fitted and secured fixedly in the housing  27 , the coil spring  33  attached to the inside of casing  67  and an inner sleeve or cylinder secured at the inside end of the coil spring  33 . The sleeve is fixedly attached to the shaft or pin  69 , so that the coil spring  33  wraps or unwraps around the sleeve and around the shaft  69  as the wheel  61  rotates. 
     As best seen in  FIG. 5 , which shows the embodiment displayed in  FIG. 6  from a user&#39;s perspective, the outer housing  27  hides from view the coil spring assembly  67  and wheel component  61  of the pusher device  13 , so that only the rod  11  and housing  27  of the apparatus  13  are visible when viewing the unit from the front end of the rod. 
     Similarly,  FIG. 7  depicts a detail side view of the pusher apparatus from a user&#39;s perspective. The outer housing  27  hides the coil spring mechanism  33  and wheel  61  from view, so that only the rod  11  and the end of shaft or pin  69  are visible. 
     The coil spring mechanism  33  is a standard coiled flat spring or power spring oriented in the housing so that the coil is wound tighter or charged by the wheel  61  rolling along the rod  11  as the unit is pushed back from the front of the rod  11 . As a result, the coil spring  33  when it tries to unwind turns the wheel  61  to roll along the rod  11  and urges the unit  13  to move toward the front end of the rod  11 . The coil spring is selected so that the force that the pusher unit  13  applies as it is urged to the end of the rod  11  is such that it is capable of pushing the product hanging on the rod  11  to the front, but not so great a force that the product can be pushed completely off the distal end  11   a . The amount of force that is appropriate is dependent on the weight of the product displayed, and accordingly the spring and/or wheel of pusher unit  13  must be preselected for a given application to have the correct amount of force. The force applied by the pusher unit  13  to the product preferably varies from about 0.5 pounds to about 5 pounds, depending on the application, e.g., the weight of the packages  23  on the display. 
     In addition, the coil spring is preferably a constant force spring, meaning that it produces the same amount of rotational force on the wheel  61  no matter how tightly it is wound or charged. Alternatively, however, it may be desirable to provide a variable force spring, also readily available on the market, which increases the force applied to the wheel  61  and by the pusher unit  13  the farther back the pusher unit  13  is moved and the tighter it is wound. The higher force likely corresponds to a greater weight of product to be pushed when the rod  11  is completely filled with product, as compared to less force expected necessary when the rod  11  supports only a small amount of product. In addition, a variable force spring may be adjusted in the force output by rotating the position of the spring as it is held in the housing  27 . 
     As best seen in  FIG. 7 to 9 , in the preferred embodiment of the apparatus, the outer housing  27  is shaped in the form of a square with one rounded corner  70  that outlines the circumference of the coil spring  65 . This particular configuration of the outer housing is aesthetically pleasing, and further requires less material to make than a completely square-shaped outer housing. 
       FIG. 8  depicts a detail section view along line  8 - 8  of  FIG. 6 , and shows the coil spring attached at an inner end to a sleeve  35  affixed to the shaft  69 , which is fixedly connected with configured to rotate with the wheel  61 . The coil spring mechanism is a self-contained unit comprising an outer casing  67  that fits into a conforming opening in the housing  27 . Inside the outer casing  67 , the outer end of the spring  65  is fixed to the outer casing  67 , and coils radially inward inside the casing  67 . The inner end of the coil spring  65  is fixedly secured to sleeve  35  so that rotation of the inner sleeve  35  relative to the outer casing  67  coils the spring tighter, charging the spring to bias the sleeve  69  to rotate relative to the outer casing  67  in the opposite direction. The sleeve  69  fixedly holds therein shaft  69  so that they rotate together, and shaft  69  is biased or urged to rotate. The coil spring  65  is in an arrangement or orientation such that the spring tightens as the inner end of the spring is wrapped around the shaft and sleeve  69  as the wheel traverses the rod  11  rearward, and so that the spring discharges and urges or biases the wheel to rotate and roll the wheel forward to the distal end of the rod  11 . 
       FIG. 9  depicts a detail section view along line  9 - 9  of  FIG. 6 , and shows the wheel  61  moving along the rod  11 . It is especially important the contact between the wheel  61  and the rod  11  be high friction so that the force from the spring is transmitted efficiently to move the pusher unit  13  forward. In the preferred embodiment of the pusher apparatus, the wheel  61  and the rod  11  have coacting engagement structures to accomplish this. The engagement structures take the form of coacting gear-like teeth, wherein teeth generally indicated at  90  on the rod correspond to teeth generally indicated at  92  on the wheel  61 , so as to maximize friction between the wheel  61  and the rod  11  as the wheel  61  traverses the rod. In addition, the teeth  90 ,  92 , allow for the wheel  61  to maintain constant engagement with the rod  11 , and also prevent the pusher unit  13  from advancing off the rod  11  completely, because the teeth  90  in the rod  11  end at a point and jam lock the wheel  61 . 
       FIG. 10  depicts an exploded partially cut-away view of the preferred embodiment of the pusher device  13 , having an outer housing  27  in the shape of a square with a rounded corner. Shaft  69  protrudes from either side of wheel  61  to which it is attached fixedly. Shaft end  69  a is rotatably received in aperture  37  in housing  27 , and wheel  61  fits into space  38  in housing  27 , which has a top opening  39  through which the wheel  61  contacts rod  11 . Coil spring assembly  65  mounts on shaft end  69   b , with the inner connection portion tongue  35  fixedly secured in slot  41  in shaft  69 . The extreme end of pin  69   b  is rotatably received in aperture  43  in end cover plate  45 . 
     The parts of the pusher device, especially the spring mechanism, which is made of metal, and the gear wheel, are preferably situated in the housing such that the center of gravity of the pusher device is below the rod or hook  11  so that the weight of the pusher device effectively maintains it in a stable position relative to the rod and the wheel stays in contact with the traction engagement surface or teeth of the underside of the rod. 
     A certain amount of frictional force or transmitting engagement force between the surface of the rod and the wheel must be maintained in order for the pusher device to be able to push products forward along the rod. For stores which are hesitant to acquire a new set of rods having the requisite surface to co-act with the wheel of the pusher device, such as gear-type teeth, another embodiment of the invention includes a retrofit sleeve that is configured so as to fit around a standard rod and provide the requisite frictional force between the surface of the sleeve and wheel so as to push products forward on the rod. 
     As depicted in  FIG. 11 , an alternate embodiment of the pusher device  101  is shown operating with a standard-issue rod  103 , which is provided with a retrofit sleeve  105  that is configured to grip the length of the rod  103  so as to remain fixed as the pusher apparatus  101  traverses the length of the sleeve  105 , thereby pushing the packaged products  107  towards the front end of the rod  108 . 
     As best seen in  FIG. 13A , the retrofit sleeve  105  is configured to snap into place around a standard display hook rod by two curved portion  109  that extend upwardly from a molded track  111  of gear teeth sized to coact with the gear toothed wheel of the pusher unit  101 . The entire sleeve is preferably made in plastic, and is dimensioned to fit through the standard product packaging hole  113  (see  FIG. 12 ) when placed on a rod  103 . 
       FIG. 13B  discloses an alternate embodiment of the sleeve  114 , which also is a molded plastic part that is configured to snap on securely to the rod  11 . The track  116  has coacting teeth  118  defined by recesses  120  formed in the sleeve  114 . 
     Pusher apparatus  101  contains a similar coil spring and gear wheel to the previous embodiment, and works in a similar way. As best depicted in  FIG. 14 , the pusher unit  111  contains the gear-toothed wheel  115  and the coil spring  117  both mounted on axle shaft  119  positioned below the rod  103  within housing  121 . 
       FIG. 15  depicts a further an aspect of the embodiment in which the housing  121  has a hinge  123 , which allows the pusher device  101  to easily be opened and closed for installation or assembly. The hinged top  125  is secured when closed by bolt or rivet  127 . 
       FIG. 16  depicts a further embodiment of the present invention in which the wheel  131  is made out of rubber, or some other material having a high coefficient of friction, or else has at least a contact surface of such a material for the rod  133 , so as to maintain the requisite frictional force between the rod  133  and the wheel  131  to move the pusher unit  135  forward based on the force generated by coil spring  137 . 
       FIG. 17  is an exploded view of yet another embodiment of the invention, in which the outer housing is of two three faced parts  141  and  143 . Gear toothed wheel  145  is mounted on a pin  147  with a slot that receives and holds secured fixedly the inner end tongue  148  of coil spring assembly  151 . 
     During assembly, the housing parts are placed over the rod  157  so that the rod  157  extends through openings  159 . The two parts  141  and  143  are then assembled so that the lateral ends of pin  147  extend through openings  153  and  155  in the housing parts  141  and  143 . Wheel  145  automatically aligns with the teeth of rod  157 . The coil spring assembly  151  is immobilized in the housing by a portion of the housing (not shown) that receives the outer tongue  149  of spring with a portion or portions in the housing part  141 . 
       FIG. 18  shows a particularly advantageous alternate embodiment of the invention. An external housing  201 , configured to contain the mechanism depends on the hook rod  203  as the above embodiments do. A first gear wheel  205  is fixedly secured on rotatable shaft  207  and engages the teeth on the bottom of the rod  203 . Alternatively, a flat friction roller or a retrofit sleeve with teeth may be used on the rod, as discussed herein previously. A step-up gear wheel  209  is also fixedly secured on shaft  207  so as to rotate therewith, and so that both toothed gear wheels  205  and  209  are constrained to turn together. 
     Gear wheel  209  has teeth that meshingly engage with the teeth of toothed gear wheel  211 , which is supported for rotation on shaft  213  in housing  201 . Gear wheel  211  is connected with one end  215  of torsion spring  217 , the other end  219  of which is secured in the housing  201 . Rotation of wheel  211  in one direction tightens the spring  217 , and the spring  217  biases the wheel to turn in the other direction. 
     When housing  201  is pushed to the back of the rod  203 , it rotates wheel  205  together with gear wheel  209 . Gear wheel  209  in turn rotates wheel  211 , which tightens spring  217 . As product is removed from the rod  203 , the force from spring  217  is transmitted to wheel  211 , to wheel  209 , to wheel  205 , resulting in a force urging the housing  201  forward on the rod  203 . 
     The torsion spring  217  usually has a limited operative range of motion of about 360 degrees, and the usual rod  203  is of a length that several turns of the wheel  205  are needed to roll the pusher to the forward end of the rod. The step-up wheel  209  serves to convert the 360 degrees of discharge rotation of spring  217  transferred to wheel  211  into several rotations, preferably four, of the wheel  205 . The force constant of the spring is selected such that the force conferred to the rod  203  is appropriate so as to move the product forward without pushing it off the rod  203 . 
     It will be understood that the invention herein extends well beyond the embodiments of the disclosure, and the terms used in this specification should be understood to be language of description, not limitation, as those of skill in the art with this specification before them will be able to make changes and modifications therein without departing from the spirit of the invention.