U.S. patent application number 17/323570 was filed with the patent office on 2021-12-23 for tote system for facilitating retail pick-up orders.
The applicant listed for this patent is H-E-B, LP. Invention is credited to Joaquin Briones, III, Gokul Jegadeesh, Jin Li, Johanna Stechschulte.
Application Number | 20210394957 17/323570 |
Document ID | / |
Family ID | 1000005641574 |
Filed Date | 2021-12-23 |
United States Patent
Application |
20210394957 |
Kind Code |
A1 |
Stechschulte; Johanna ; et
al. |
December 23, 2021 |
TOTE SYSTEM FOR FACILITATING RETAIL PICK-UP ORDERS
Abstract
A tote and tote system providing for more efficient retail order
pick-ups is disclosed. In certain embodiments, a tote may comprise
a bottom panel for supporting one or more retail items, a rear
panel and a front panel, wherein the front panel comprises an
opening for accessing the one or more retail items of the tote, a
first and a second side panel, and one or more bale arms positioned
across a top of the tote, wherein the one or more bale arms each
comprise a substantially horizontal portion extending from the
first side panel to the second side panel, such that the one or
more bale arms are operable to support another tote stacked on top
of the tote.
Inventors: |
Stechschulte; Johanna;
(Canyon Lake, TX) ; Briones, III; Joaquin; (San
Antonio, TX) ; Li; Jin; (San Antonio, TX) ;
Jegadeesh; Gokul; (Chicago, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
H-E-B, LP |
San Antonio |
TX |
US |
|
|
Family ID: |
1000005641574 |
Appl. No.: |
17/323570 |
Filed: |
May 18, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16904429 |
Jun 17, 2020 |
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17323570 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 5/068 20130101;
B65D 71/0088 20130101; B65D 21/0233 20130101; B65D 21/062 20130101;
B65B 69/00 20130101; B65D 21/0212 20130101 |
International
Class: |
B65D 21/06 20060101
B65D021/06; B65B 5/06 20060101 B65B005/06; B65B 69/00 20060101
B65B069/00; B65D 21/02 20060101 B65D021/02; B65D 71/00 20060101
B65D071/00 |
Claims
1. A tote, comprising: a bottom panel for supporting one or more
retail items; a rear panel and a front panel, wherein the front
panel comprises an opening for accessing the one or more retail
items of the tote; a first and a second side panel; and one or more
bale arms positioned across a top of the tote, wherein the one or
more bale arms extend from the first side panel to the second side
panel, such that the one or more bale arms are operable to support
another tote stacked on top of the tote.
2. The tote of claim 1, wherein the first side panel and the second
side panel each comprise one or more slots along a top edge of the
first and second side panels.
3. The tote of claim 2, wherein the one or more bale arms are
rotatable from a first position to a second position, wherein in
the first position, the one or more bale arms are positioned in the
one or more slots.
4. The tote of claim 3, wherein in the second position, the one or
more bale arms are not positioned across the top of the tote.
5. The tote of claim 1, wherein the tote further comprises a nest
stop positioned on a at least one of a side panel and a rear panel
of the tote.
6. The tote of claim 1, wherein the tote further comprises a
lid.
7. The tote of claim 6, wherein the lid comprises a first lid panel
and a second lid panel, and wherein the first lid panel may be
coupled to the second lid panel via one or more connectors.
8. The tote of claim 7, wherein the lid may be positioned in an
open position and a closed position, and wherein in a closed
position, the first and second lid panels are supported by at least
one bale arm and the rear panel.
9. The tote of claim 6, wherein the lid comprises a key
connector.
10. The tote of claim 9, wherein the bottom panel comprises a key
slot.
11. The tote of claim 6, wherein the lid comprises an opening and
at least one of the first and second side panels comprises a
protrusion for coupling to the opening of the lid.
12. The tote of claim 1, wherein the one or more bale arms are
rotatable between a first position and a second position, and
wherein the first position allows another tote to be stacked on top
of the tote, and wherein the second position allows another tote to
be nested within the tote.
13. The tote of claim 1, further comprising a latch coupled to the
rear panel, wherein the latch is operable to secure at least one
bale arm against the rear panel.
14. A tote system, comprising: two or more totes, wherein each of
the two or more totes comprises one or more bale arms and a front
panel comprising an opening for accessing one or more retail items;
wherein the one or more bale arms are rotatable between a first
position and a second position; wherein the two or more totes
comprise a first tote and a second tote, and wherein the second
tote is stacked on top of the one or more bale arms of the first
tote when the one or more bale arms of the first tote are in a
first position.
15. The tote system of claim 14, further comprising: a third tote
stacked on top of the one or more bale arms of the second tote when
the one or more bale arms of the second tote are in a first
position.
16. The tote system of claim 14, further comprising a pallet,
wherein the two or more totes are positioned on the pallet.
17. A method of facilitating retail pick-up orders, comprising:
stacking two or more totes in a first column of totes via one or
more bale arms of the two or more totes, wherein each of the two or
more totes in the first column has an opening such that an operator
may place retail items in each of the two or more totes while the
two or more totes are stacked, and wherein the one or more bale
arms are rotatable between a first position and a second position;
and placing retail items in at least one of the two or more totes
corresponding to one or more retail orders for fulfillment.
18. The method of claim 17, further comprising: removing one or
more retail items from at least one of the two or more totes via
the opening, wherein the one or more retail items correspond to one
or more retail orders for customer pick-up.
19. The method of claim 17, further comprising: removing one or
more retail items from the at least one of the two or more totes
such that the at least one of the two or more totes is an empty
tote; rotating the one or more bale arms of the empty tote from a
first position to a second position; and nesting the empty tote in
another empty tote.
20. The method of claim 17, further comprising: stacking two or
more totes in a second column of totes via one or more bale arms of
the two or more totes; and positioning a second column of two or
more totes adjacent to the first column of two or more totes.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of and is a
continuation-in-part application of U.S. application Ser. No.
16/904,429 filed on Jun. 17, 2020, which is incorporated by
reference in its entirety for all purposes.
BACKGROUND
[0002] The present disclosure generally relates to systems and
methods for fulfilling orders for items sold by retailers, and more
particularly, to a novel tote and tote system for facilitating
retail pick-up orders.
[0003] It is common for retailers of goods and services to both own
and/or operate one or more "brick-and-mortar" retail stores and/or
physical facilities where customers may browse, purchase, and/or
pick up items at the site, and also provide an online website or
other service for receiving orders from customers remotely. Today's
consumers demand convenience, speed, selection, and high-quality
from their retailers regardless of whether such consumers are
shopping online or are shopping in a brick-and-mortar
establishment. Thus, in order to maximize customer satisfaction, a
retailer must meet consumer expectations on these attributes when
fulfilling items to a customer via customer pick-up.
[0004] A common method of facilitating customer pick-ups is by
preparing retail items in a staging area, such as a warehouse, and
storing them in containers, often referred to as "totes." Prior
totes are typically enclosed storage containers, and may comprise
lids for accessing the retail items inside of the totes. Retail
items in traditional totes are typically stored in stacked columns
to efficiently use space in a staging area or other fulfillment
location until the customer arrives to pick up the order. However,
providing efficient pick-ups for the customer may prove difficult
when customer arrival times are unpredictable. Retail items sitting
on totes awaiting customer arrivals are "down-stacked" as
additional items are loaded in the totes for pick-up. Thus, unless
a customer's order is in a tote that sits at the top of a stacked
column, un-stacking of totes may be required to get a specific tote
or totes containing a customer's retail order. After a customer's
order is retrieved and the down-stacked tote is extracted, the
entire tote system must be re-stacked. Such down-stacking,
un-stacking, and re-stacking leads to inefficiencies in fulfilling
retail order pick-ups.
[0005] One method to avoid down-stacking may be to place the totes
in perfect sequence based on customer pick-up times. However, a
single delayed or off-scheduled customer arrival time can cause the
down-stacking issues described above. Another method may be to use
multi-level static shelves so that no down-stacking is needed to
access a specific tote for the arrived customer. However, space in
a warehouse or fulfillment area is often at a premium, and static
shelves take up the same amount of space even when
underutilized--that is, when fewer totes are required at a given
time. This inflexibility may negatively impact space utilization
within a staging area, warehouse, or retail location. Worse, when
demand is higher than projected or more customers are arriving than
expected at a given time, there may be an insufficient number of
shelves to hold totes such that the retail pick-up flow is
disrupted.
[0006] Furthermore, traditional totes are typically not clear or
transparent. Without opening the lid, which would be difficult for
any tote not at the very top of a column of totes, operators cannot
visually inspect which totes contain retail items and which totes
do not. An operator for a retail fulfillment location may be
expected to lift a heavy tote, for example, up to 50 lbs, on the
job, but without any visibility into the contents of a given tote,
the weight of the tote may come as a surprise and the operator may
sustain an injury or experience discomfort if the operator's body
posture is not appropriate for the weight range of the tote.
[0007] Additionally, traditional enclosed totes may result in the
degradation of retail items, for example, fresh produce that
produce ethylene (e.g., bananas, avocados, peaches, etc.). Fresh
produce items that produce ethylene may ripen more rapidly as
ethylene gas is released and stays trapped inside the traditional
totes. This could negatively impact product quality, especially in
the summer where warmer temperatures speed up the production of
ethylene gas, thus accelerating the ripening process of the produce
items. Additionally, refrigerated or frozen retail items that sit
on totes longer than expected in traditional tote systems may
experience degradation of product quality.
[0008] Traditional totes also do not provide for "nesting" of totes
on top of one another when the lids of such traditional totes are
open. Thus, these traditional tote systems do not allow for reverse
logistics during retrievals--that is, the down-stacking of empty
return totes. The ability to nest totes within one another may
allow for more efficient returns back to a warehouse or other
staging area where additional totes are needed. Valuable space
resources and personnel resources may be optimized by nestable
totes.
SUMMARY
[0009] The present disclosure generally relates to a tote system
for facilitating more efficient retail order pick-ups.
[0010] In certain embodiments, a tote may comprise a bottom panel
for supporting one or more retail items, a rear panel and a front
panel, wherein the front panel may comprise an opening for
accessing the one or more retail items of the tote, a first and a
second side panel, and one or more bale arms positioned across a
top of the tote, wherein the one or more bale arms may each
comprise a substantially horizontal portion extending from the
first side panel to the second side panel, such that the one or
more bale arms are operable to support another tote stacked on top
of the tote.
[0011] In certain embodiments, the tote may further comprise a
substantially trapezoidal shape. In certain embodiments, the first
side panel and the second side panel may be angled such that each
of the first side panel and the second side panel form an obtuse
angle with the bottom panel.
[0012] In certain embodiments, the one or more bale arms may be
rotatable such that the one or more bale arms are not positioned
across the top of the tote. In certain embodiments, each bale arm
may comprise a first end and a second end positioned at opposing
ends from one another. In certain embodiments, the second end may
be wider than the first end. In certain embodiments, the first end
may be angled more than 90 degrees from the horizontal portion of
the bale arm, and the second end may be angled substantially
perpendicular to the horizontal portion of the bale arm.
[0013] In certain embodiments, the tote may further comprise a
first bale arm and a second bale arm, and wherein the first end of
the first bale arm and the second end of the second bale arm are
positioned along the first side panel, and wherein the second end
of the first bale arm and the first end of the second bale arm are
positioned along the second side panel. In certain embodiments, the
first side panel and the second side panel of the tote may each
comprise a hand hold.
[0014] In certain embodiments, a tote system may comprise two or
more totes, including a first tote and a second tote, wherein each
of the two or more totes may comprise one or more bale arms. In
certain embodiments, the first tote and the second tote may be
aligned substantially adjacent to one another, and at least one
bale arm of the first tote may interlock with at least one bale arm
of the second tote.
[0015] In certain embodiments, the two or more totes may each
comprise a first bale arm and a second bale arm. In certain
embodiments, the first bale arm and the second bale arm may each
comprise a first end and a second end, wherein the second end is
wider than the first end. In certain embodiments, the first end of
the first bale arm of the first tote may interlock with the second
end of the first bale arm of the second tote. In certain
embodiments, the second end of the second bale arm of the first
tote may interlock with the first end of the second bale arm of the
second tote.
[0016] In certain embodiments, a tote system may further comprise a
third tote stacked substantially on top of the one or more bale
arms of the first tote and a fourth tote stacked substantially on
top of the one or more bale arms of the second tote, and at least
one bale arm of the third tote may interlock with at least one bale
arm of the fourth tote. In certain embodiments, the tote system
further comprises a pallet, wherein the two or more totes are
positioned on the pallet.
[0017] In certain embodiments, a method for facilitating retail
pick-up orders may comprise stacking two or more totes in a first
column of totes via one or more bale arms of the two or more totes,
wherein each of the two or more totes in the first column may have
an opening such that an operator may place retail items while the
two or more totes are stacked, stacking two or more totes in a
second column of totes via one or more bale arms of the two or more
totes, wherein each of the two or more totes in the second column
may have an opening such that an operator may place retail items
while the two or more totes are stacked, positioning the first and
second column of totes adjacent to one another, interlocking one or
more bale arms of a first tote in the first column with one or more
bale arms of a second tote in the second column, wherein the second
tote is immediately adjacent to the first tote; placing retail
items in at least one of the two or more totes corresponding to one
or more retail orders. In certain embodiments, each of the one or
more bale arms may be positioned across a top of each tote of the
two or more totes, such that a stacked tote may be substantially
supported by the one or more bale arms of a tote immediately below
the stacked tote.
[0018] In certain embodiments, the method for facilitating retail
pick-up orders may further comprise removing one or more retail
items from at least one of the two or more totes via the opening,
wherein the one or more retail items correspond to one or more
retail orders for customer pick-up. In certain embodiments, the
method for facilitating retail pick-up orders may further comprise
removing one or more retail items from the at least one of the two
or more totes such that the at least one of the two or more totes
is an empty tote, rotating the one or more bale arms of the empty
tote such that the bale arms are not positioned across the top of
the empty tote, and nesting the empty tote in another empty tote.
In certain embodiments, the first column of totes and the second
column of totes may each comprise six stacked totes.
[0019] In certain embodiments, the method for facilitating retail
pick-up orders may further comprise stacking totes two or more
totes in a third column of totes via one or more bale arms of the
two or more totes, and interlocking the one or more bale arms of
the second tote in the second column with one or more bale arms of
a third tote in the third column of totes, wherein the third tote
is immediately adjacent to the second tote. In certain embodiments,
at least one of the two or more totes may comprise corrugated
plastic.
[0020] In certain embodiments, a tote may comprising a bottom panel
for supporting one or more retail items, a rear panel and a front
panel, wherein the front panel comprises an opening for accessing
the one or more retail items of the tote; a first and a second side
panel; and one or more bale arms positioned across a top of the
tote, wherein the one or more bale arms extend from the first side
panel to the second side panel, such that the one or more bale arms
are operable to support another tote stacked on top of the
tote.
[0021] In certain embodiments, the first side panel and the second
side panel each comprise one or more slots along a top edge of the
first and second side panels. In certain embodiments, the one or
more bale arms are rotatable from a first position to a second
position, wherein in the first position, the one or more bale arms
are positioned in the one or more slots. In certain embodiments, in
the second position, the one or more bale arms are not positioned
across the top of the tote. In certain embodiments, the tote may
further comprise a nest stop positioned on at least one of a side
panel and a rear panel of the tote.
[0022] In certain embodiments, the tote may further comprise a lid.
In certain embodiments, the lid may comprise comprises a first lid
panel and a second lid panel, and wherein the first lid panel may
be coupled to the second lid panel via one or more connectors. In
certain embodiments, the lid may be positioned in an open position
and a closed position, and wherein in a closed position, the first
and second lid panels may be supported by at least one bale arm and
the rear panel. In certain embodiments, the lid may comprise a key
connector. In certain embodiments, the bottom panel may comprise a
key slot. In certain embodiments, the lid may comprise an opening
and at least one of the first and second side panels may comprise a
protrusion for coupling to the opening of the lid.
[0023] In certain embodiments, the one or more bale arms may be
rotatable between a first position and a second position, and
wherein the first position allows another tote to be stacked on top
of the tote, and wherein the second position allows another tote to
be nested within the tote. In certain embodiments, the tote may
comprise a latch coupled to the rear panel, wherein the latch is
operable to secure at least one bale arm against the rear
panel.
[0024] In certain embodiments, a tote system, may comprise two or
more totes, wherein each of the two or more totes comprises one or
more bale arms and a front panel comprising an opening for
accessing one or more retail items, wherein the one or more bale
arms are rotatable between a first position and a second position,
and wherein the two or more totes comprise a first tote and a
second tote, and wherein the second tote is stacked on top of the
one or more bale arms of the first tote when the one or more bale
arms of the first tote are in a first position.
[0025] In certain embodiments, the tote system may further comprise
a third tote stacked on top of the one or more bale arms of the
second tote when the one or more bale arms of the second tote are
in a first position. In certain embodiments, the tote system may
further comprise a pallet, wherein the two or more totes are
positioned on the pallet.
[0026] In certain embodiments, a method of facilitating retail
pick-up orders may comprise stacking two or more totes in a first
column of totes via one or more bale arms of the two or more totes,
wherein each of the two or more totes in the first column has an
opening such that an operator may place retail items in each of the
two or more totes while the two or more totes are stacked, and
wherein the one or more bale arms are rotatable between a first
position and a second position, and placing retail items in at
least one of the two or more totes corresponding to one or more
retail orders for fulfillment.
[0027] In certain embodiments, the method of facilitating pick-up
orders may further comprise removing one or more retail items from
at least one of the two or more totes via the opening, wherein the
one or more retail items correspond to one or more retail orders
for customer pick-up. In certain embodiments, the method of
facilitating pick-up orders may further comprise removing one or
more retail items from the at least one of the two or more totes
such that the at least one of the two or more totes is an empty
tote, rotating the one or more bale arms of the empty tote from a
first position to a second position, and nesting the empty tote in
another empty tote. In certain embodiments, the method of
facilitating pick-up orders may further comprise stacking two or
more totes in a second column of totes via one or more bale arms of
the two or more totes and positioning a second column of two or
more totes adjacent to the first column of two or more totes.
BRIEF DESCRIPTION OF THE FIGURES
[0028] For a more complete understanding of the present disclosure
and its features and advantages, reference is now made to the
following description, taken in conjunction with the accompanying
drawings, in which:
[0029] FIG. 1A is an isometric view of a tote according to certain
embodiments of the present disclosure.
[0030] FIG. 1B is a top view of a tote according to certain
embodiments of the present disclosure.
[0031] FIG. 1C is a front view of a tote according to certain
embodiments of the present disclosure.
[0032] FIG. 1D is a rear view of a tote according to certain
embodiments of the present disclosure.
[0033] FIG. 1E is a first side view of a tote according to certain
embodiments of the present disclosure.
[0034] FIG. 1F is a second side view of a tote according to certain
embodiments of the present disclosure.
[0035] FIG. 2A is a front view of a bale arm of a tote according to
certain embodiments of the present disclosure.
[0036] FIG. 2B is a first side view of a bale arm of a tote
according to certain embodiments of the present disclosure.
[0037] FIG. 2C is a second side view of a bale arm of a tote
according to certain embodiments of the present disclosure.
[0038] FIG. 2D is a rear view of a bale arm of a tote according to
certain embodiments of the present disclosure.
[0039] FIG. 3A is a side-by-side tote configuration with
pre-interlocking bale arms according to certain embodiments of the
present disclosure.
[0040] FIG. 3B is a side-by-side tote configuration with
interlocking bale arms according to certain embodiments of the
present disclosure.
[0041] FIG. 4 is a representation of a stacked tote configuration
according to certain embodiments of the present disclosure.
[0042] FIG. 5 is a representation of a tote system according to
certain embodiments of the present disclosure.
[0043] FIG. 6 is a side-by-side tote configuration with
interlocking bale arms according to certain embodiments of the
present disclosure.
[0044] FIG. 7 is a representation of a nested tote configuration
according to certain embodiments of the present disclosure.
[0045] FIG. 8A is an isometric view of a tote according to certain
embodiments of the present disclosure.
[0046] FIG. 8B is a front view of a tote according to certain
embodiments of the present disclosure.
[0047] FIG. 8C is a side view of a tote according to certain
embodiments of the present disclosure.
[0048] FIG. 8D is a bottom view of a tote according to certain
embodiments of the present disclosure.
[0049] FIG. 9A is an isometric view of a tote according to certain
embodiments of the present disclosure.
[0050] FIG. 9B is a front view of a tote according to certain
embodiments of the present disclosure.
[0051] FIG. 9C is a side view of a tote according to certain
embodiments of the present disclosure.
[0052] FIG. 9D is a corner view of a tote according to certain
embodiments of the present disclosure.
[0053] While the present disclosure is susceptible to various
modifications and alternative forms, specific example embodiments
have been shown in the figures and are herein described in more
detail. It should be understood, however, that the description of
specific example embodiments is not intended to limit the invention
to the particular forms disclosed, but on the contrary, this
disclosure is to cover all modifications and equivalents as
illustrated, in part, by the appended claims.
DESCRIPTION OF EMBODIMENTS
[0054] Illustrative embodiments of the present disclosure are
described in detail herein. In the interest of clarity, not all
features of an actual implementation are described in this
specification. It will of course be appreciated that in the
development of any such actual embodiment, numerous
implementation-specific decisions must be made to achieve the
developers' specific goals, such as compliance with system related
and business-related constraints, which will vary from one
implementation to another. Moreover, it will be appreciated that
such a development effort might be complex and time consuming but
would nevertheless be a routine undertaking for those of ordinary
skill in the art having the benefit of the present disclosure.
Furthermore, in no way should the following examples be read to
limit, or define, the scope of the disclosure.
[0055] Referring now to FIG. 1A, a tote 100 is shown. A tote 100
may be comprised of any material suitable to store retail goods,
including ambient and chilled retail goods. As would be understood
by one of ordinary skill in the art, the material selected should
be durable enough to withstand the stacking arrangement of totes
100 as described in more detail below with respect to FIG. 3. The
material selected should be lightweight so as to be easy to lift
and transport but also be substantially rigid to provide support
for the retail goods stored in the tote 100. Furthermore, the
material should be impact resistant such that damage to the tote
100 is minimized if a tote 100 is dropped or otherwise impacted. In
certain embodiments, tote 100 may be comprised of plastic, for
example, corrugated plastic or molded plastic. Corrugated plastic
may be more flexible or agile than molded plastic because
dimensions of corrugated plastic totes may be easily changed in
production without building a new mold. Thus, corrugated plastic
may be more easily adapted to fit the needs of a given retail space
or fulfillment area, for example, if changes need to be made based
on the size or volume of the corrugated plastic totes. The
corrugated plastic may be comprised of solid polypropylene. In
other embodiments, tote 100 may be comprised of other types of
plastic, for example, tote 100 may be comprised of
acrylonitrile-butadiene-styrene (ABS), acrylics, polyethylene (PE),
high density polyethylene (HDPE), polypropylene (PP), &
polyvinyl chloride (PVC), low-density polyethylene (LDPE), or any
other type of plastic. Tote 100 may be pressed or formed from a
single congruous piece of corrugated plastic, with or without the
use of any adhesives. In other embodiments, tote 100 may be
comprised of multiple pieces or layers of corrugated plastic formed
together.
[0056] Tote 100 may be substantially rectangular or trapezoidal. In
certain embodiments, tote 100 may comprise one or more flaps 110.
In certain embodiments, the flaps 110 of tote 100 may be folded
over and attached to the body of tote 100 using sonic welds.
Welding the flaps may help keep bale arms 200a and 200b (discussed
in more detail below) in place, while also increasing the longevity
of the tote 100. In certain embodiments, flaps 110 of tote 100 may
be secured using an adhesive (not shown). However, sonic welds may
be more appropriate to withstand the force of the bale arms 200 as
they are flipped inwards and outwards, or when the totes 100 are
stacked or nested (discussed in more detail below). Furthermore,
sonic welds may provide more stability to the tote 100, especially
while being transported or otherwise handled by an operator.
[0057] As shown in FIG. 1A, tote 100 may comprise a bottom panel
120, side panels 125a and 125b, and a rear panel 130. Side panels
125 may each comprise a hand hold 140 to facilitate easy transport
of the tote 100. Tote 100 may further comprise a front panel 135
that is substantially comprised of an opening or window for
inserting and removing goods from the tote 100. Tote 100 may
further comprise one or more bale arms 200, for example, bale arms
200a and 200b, described in further detail with respect to FIGS.
2A-2D. One or more bale arms 200 may be partially enclosed by the
tote 100, as shown in FIG. 1A. In certain embodiments, one or more
bale arms 200 may be partially enclosed between the body of tote
100 and the flaps 110. In certain embodiments, each tote 100 may
comprise a first bale arm 200a and a second bale arm 200b. A
portion of bale arms 200 may be positioned across the top of tote
100 and extending between side panels 125, such that another tote
100, may be positioned on or stack on top of first bale arm 200a
and second bale arm 200b. As described in more detail below with
respect to FIG. 3, the "stacked" nature of one or more totes 100
may provide for more structural stability of the tote system.
[0058] FIG. 1B is an overhead view of tote 100. Bottom panel 120 of
tote 100 may support the retail goods in tote 100. In certain
embodiments, bottom panel 120 may comprise a thicker material than
other parts of the tote 100. For example, bottom panel may have an
extra layer of corrugated plastic (not shown) to strengthen the
bottom panel 120 and hold the weight of the retail items without
deformation to the bottom panel 120 or the tote 100. An extra layer
of corrugated plastic may be attached to bottom panel 120 by an
adhesive or may be welded. The extra layer of corrugated plastic
may be substantially smooth such that retail items placed on bottom
panel 120 are not damaged during transportation or storage. The
extra layer of corrugated plastic may comprise a substantially
smooth surface so that bottom panel 120 is easier to sanitize.
[0059] Side panels 125 and rear panel 130 may substantially enclose
the retail goods stored in tote 100 such that when subjected to
movement, retail goods do not fall out of the tote 100. In certain
embodiments, length L.sub.t along the top of tote 100 may be
approximately 24 inches and width W.sub.t along the top of tote 100
may be approximately 13 inches. However, as would be understood by
one of ordinary skill in the art, any length L.sub.t or width
W.sub.t may be appropriate in keeping with the design features and
benefits of the present disclosure. For example, in certain
embodiments, length L.sub.t of tote 100 may be 10-40 inches, and
width W.sub.t of tote 100 may be 5-25 inches. The length L.sub.t
and width W.sub.t may be varied or selected based on one or more,
for example, the size, weight, shape, or type of retail goods
stored in tote 100. For example, for large or bulky retail items, a
tote 100 with larger length and width dimensions may be required.
Unlike traditional totes, tote 100 may not comprise a lid or panel
covering the top of the tote 100. The lack of lid or cover may
allow an operator to visually inspect what retail items are located
in the tote 100 before lifting or moving the tote 100, such that
the operator may use the appropriate body motion or posture before
lifting or moving the tote 100.
[0060] FIG. 1C is a front view of a tote 100 and FIG. 1D is a rear
view of a tote 100. In certain embodiments, tote 100 may have a
height H of approximately 12.75 inches. As would be understood by
one of ordinary skill in the art, any height H may be appropriate
in keeping with the design features and benefits of the present
disclosure. For example, in certain embodiments, height H of tote
100 may be 5-25 inches. The height H may be varied or selected
based on one or more factors, for example, the size, weight, shape,
or type of retail goods stored in tote 100. For example, for tall
items, a tote 100 with a larger height dimension may be required.
In certain embodiments, tote 100 may be substantially trapezoidal
in shape. In certain embodiments, front panel 135 and rear panel
130 may have a width W.sub.t along a top edge 132 and a width
W.sub.b along a bottom edge 131, where W.sub.t may be longer than
W.sub.b. For example, in certain embodiments where width W.sub.t
along top edge 132 is approximately 13 inches, width W.sub.b along
bottom edge 131 may be approximately 11 inches. Additionally, side
edge 133 of rear panel 130 and front panel 135 may form an obtuse
angle .PHI..sub.1 with bottom edge 131 that is slightly more than
90 degrees, for example, approximately 94 degrees. As would be
understood by one of ordinary skill in the art, .PHI..sub.1,
W.sub.t, and W.sub.b may be varied in keeping with aspects of the
present disclosure. For example, in certain embodiments,
.PHI..sub.1 may be 95, 100, or 105 degrees. In certain embodiments,
the substantially trapezoidal shape of tote 100 may provide for
stackable and nestable features of one or more totes 100, as
described in more detail below with respect to FIGS. 4 and 7,
respectively.
[0061] Front panel 135 may substantially comprise an opening 137 or
window for placing and removing retail items from the tote 100.
Additionally, the opening or window 137 of front panel 135 may
allow an operator to visually inspect what retail items are in the
tote 100 without removing the tote 100 from a stacked
configuration, as described in more detail below. The opening or
window 137 of front panel 135 may further allow an operator to
determine the requisite amount of force and correct body posture
for lifting the tote 100 based on the items contained with the tote
100. As shown in FIG. 1D, rear panel 130 may be a solid panel and
may not be comprised of an opening or window 137. As would be
understood by one of ordinary skill in the art, in certain
embodiments, rear panel 130 may similarly comprise an opening or
window 137 for placing or removing retail items from the tote 100,
similar to front panel 135 (not shown).
[0062] The dimensions of tote 100 including height H and thickness
T may be selected based on one or more factors such as the size,
weight, shape, or type of the goods stored in tote 100. In certain
embodiments, bottom panel 120 may have a thickness T of
approximately 2.25 inches. As would be understood by one of
ordinary skill in the art, any thickness T may be appropriate in
keeping with the design features and benefits of the present
disclosure. For example, in certain embodiments, thickness T of
tote 100 may be 0.5 inch to 5 inches. The thickness T may be varied
or selected based on one or more factors, for example, the size,
weight, shape, or type of retail goods stored in tote 100. For
example, for heavy or bulky retail items, a tote 100 with a larger
thickness T may be required. In certain embodiments, the dimensions
of tote 100 may be selected in order to hold a minimum weight of
retail items. For example, dimensions of tote 100 may be selected
such that tote 100 may be able to hold 10, 20, 25, 50, or 100
pounds of retail items without showing any signs of wear and tear
on the tote 100.
[0063] The specific dimensions of tote 100 including height H and
thickness T, may be varied or selected based on the desired height
H' of the opening of front panel 135. For example, as shown in FIG.
1C, a thickness T 2.25 inches of bottom panel 120 and a height H of
12.75 of front panel 135 inches renders a height H' of 10.5 inches
of the opening 137 of tote 100. Height H' may be selected such that
there is sufficient clearance for the retail items that are to be
place in tote 100. As would be understood by one of ordinary skill
in the art, height H' may be varied based on one or more factors,
for example, the size, shape, or type of the retail items to be
stored in tote 100. In certain embodiments, height H' may be
anywhere from 5-25 inches.
[0064] FIGS. 1C and 1D are side views of tote 100. As discussed
above, tote 100 may be substantially trapezoidal in shape. In
certain embodiments, side panels 125 may have a length L.sub.t
along a top edge 127 and a length L.sub.b along a bottom edge 126,
where L.sub.t may be longer than L.sub.b. For example, in certain
embodiments where length L.sub.t along top edge 127 is
approximately 24 inches, length L.sub.b along bottom edge 126 may
be approximately 21 inches. Additionally, side edge 132 of side
panel 125 may form an obtuse angle .PHI..sub.2 with bottom edge 126
of approximately 97 degrees. As would be understood by one of
ordinary skill in the art, .PHI..sub.2, L.sub.t, and L.sub.b may be
varied in keeping with aspects of the present disclosure. For
example, in certain embodiments, .PHI..sub.2 may be 95, 100, or 105
degrees. In certain embodiments, the obtuse angle 12 and
trapezoidal shape of tote 100 may provide for stackable and
nestable features of one or more totes 100, as described in more
detail below with respect to FIGS. 4 and 7, respectively.
[0065] In certain embodiments, tote 100 may comprise hand holds 140
at or near the top of side panels 125. For example, in certain
embodiments, hand holds 125 may be located approximately 1-1.5
inches from the top of side panels 125. Hand holds 140 may
facilitate easier transport of totes 100. Tote 100 may further
comprise a label (not shown). A label (not shown) may comprise a
barcode, stockkeeping unit number, universal product code (UPC), QR
code, or any other identifier used to track or record the tote 100.
For example, an employee of a retail store could scan the label of
tote 100 to ensure that the tote 100 is in the correct
location.
[0066] FIG. 2A is a front view of a bale arm 200 in accordance with
certain embodiments of the present disclosure. In certain
embodiments, one or more bale arms 200 may be welded in a tote 100.
Bale arms 200 may be welded such that the bale arms 200 and tote
100 comprise one unitary structure. In certain embodiments, each
bale arm 200 may weigh approximately 0.5 pounds. However, as would
be understood by one of ordinary skill in the art, the weight of
bale arm 200 may be varied or selected based on one or more
factors, such as the size of the tote 100 or the size, weight,
shape, or type of retail items to be stored in tote 100. In certain
embodiments, bale arm 200 may be comprised of 1/4 inch
pre-galvanized steel wire. As would be understood by one of
ordinary skill in the art, in other embodiments, other sizes,
gauges, or material of wire may be appropriate. For example, in
certain embodiments, bale arm 200 may be comprised of aluminum,
stainless steel, or any metal or plastic. In certain embodiments,
other materials and gauges that provide sufficient durability and
strength to hold the weight of a tote 100 may be used.
[0067] Bale arm 200 may be comprised of a swing bar 210, a first
end 220, and a second end 230. Swing bar 210 may be substantially
horizontal and may be the primary portion of bale arm 200 used to
support a tote 100 stacked on top of swing bar 210, as discussed in
more detail with respect to FIG. 3. Swing bar 210 may comprise a
base portion 211 and inclined portions 212. Inclined portions 212
of swing bar 210 may comprise arcuate portions 214 between swing
bar 210 and first end 220 and swing bar 210 and second end 230,
respectively. In certain embodiments, arcuate portions 214 may
provide for an angle .theta..sub.2 of approximately 92 degrees
between base portion 211 and inclined portions 212, as well as
between swing bar 210 and first end 220 and between swing bar 210
and second end 230. Thus, in certain embodiments, inclined portions
212 may be substantially vertical and substantially perpendicular
to base portion 211. In certain embodiments, the length L.sub.1 of
the bale arm 200 may be approximately 15 inches. In certain
embodiments, the length L.sub.2 of swing bar 210, including base
portion 211 and inclined portions 212, may be approximately 12
inches. In certain embodiments, the length L.sub.3 of base portion
211 of swing bar 210 may be approximately 11 inches. As would be
understood by one of ordinary skill in the art, in certain
embodiments, lengths L.sub.1, L.sub.2, and L.sub.3 may be varied
based one or more factors, for example the width W.sub.t of the
tote 100.
[0068] Swing bar 210 and first end 220, and separately, swing bar
210 and second end 230, may together each comprise a "U-shape" such
that swing bar 210 and first end 220 and swing bar 210 and second
end 230 each straddle a side wall 125 of tote 100. First end 220
may comprise an upper bar 221 and one or more side portions 222.
Second end 230 may similarly comprise an upper bar 231 and one or
more side portions 232. In certain embodiments, the length of upper
bar 221 of first end 220 and upper bar 231 of second end 230 may be
varied or selected based on the thickness of side panel 125. In
other embodiments, the length of upper bar 221 of first end 220 and
upper bar 231 of second end 230 may be selected such that there is
a gap or space between first end 220 and second end 230 and side
panel 125, respectively, so that an employee may hold or pick up
the tote 100 using the first end 220 and 230. In certain
embodiments, the length of upper bar 221 of first end 220 and upper
bar 231 of second end 230 may be approximately 0.35 inches.
[0069] Second end 230 may further comprise an arcuate portion 234
between upper bar 231 and a side portion 232. In certain
embodiments, arcuate portion 234 may provide for a substantially
perpendicular angle between upper bar 231 and side portion 232,
such that side portion 232 of second end 230 is substantially
parallel to side panel 125 of tote 100. First end 220 may further
comprise an arcuate portion 224 between upper bar 221 and side
portion 222. In certain embodiments, arcuate portion 224 may
provide for an angle .theta..sub.1 of approximately 105 degrees
between upper bar 221 and side portion 222, such that side portion
222 of first end 220 is angled away from the side panel 125 of tote
100. In certain embodiments, side portion 222 of first end 220 may
form an obtuse angle with the upper bar 221. As would be understood
by one of ordinary skill in the art, the angles of arcuate portions
224 and 234 may be varied according to certain embodiments of the
present disclosure.
[0070] FIG. 2B is a side view of first end 220 of bale arm 200 in
accordance with certain embodiments of the present disclosure. In
certain embodiments, first end 220 may be a narrower end of bale
arm 200 compared to second end 230. As discussed with respect to
FIG. 2A, first end 220 may comprise one or more side portions 222,
for example, side portions 222a and 222b. One or more side portions
222 may each further comprise an angled portion 226 and vertical
portion 227. Angled portions 226 of side portion 222 may be form an
obtuse angle .theta..sub.3 of approximately 145 degrees from
vertical portions 227 of side portion 222. As would be understood
by one of ordinary skill, angle .theta..sub.3 may be varied based
on one or more factors in keeping with aspects of the present
disclosure. In certain embodiments, first end 220 may comprise a
first side portion 222a and a second side portion 222b. First side
portion 222a may comprise a first angled portion 226a and a first
vertical portion 227a. Second side portion 222b may comprise a
second angled portion 226b and a second vertical portion 227b. In
certain embodiments, first angled portion 226a and second angled
portion 226b may be different lengths such that angled portion 226a
is longer than angled portion 226b. In certain embodiments, first
vertical portion 227a and second vertical portion 227b may be
different lengths such that second vertical portion 227b is longer
than first vertical portion 227. For example, in certain
embodiments, first angled portion 226a may be approximately 1.2
inches and first vertical portion 227a may be 0.8 inches, and in
certain embodiments, second angled portion 227a may be
approximately 0.8 inches and second vertical portion 227b may be
approximately 1.2 inches.
[0071] First end 220 may further comprise a bottom bar 225 disposed
substantially horizontally in between side portions 222, and more
specifically, between vertical portions 227 of side portions 222.
Bottom bar may be coupled to vertical portions 227 via arcuate
portions 228. Similar to arcuate portions 214 of swing bar 210,
arcuate portions 228 may provide substantially perpendicular angles
between vertical portions 227 and bottom bar 225, such that bottom
bar 225 and upper bar 221 are substantially parallel. In certain
embodiments, the length L.sub.4 of first end 220 may be
approximately 2.8 inches, and the length L.sub.5 of bottom bar 225
of first end 220 may be approximately 1.8 inches.
[0072] FIG. 2C is a side view of second end 230 of bale arm 200 in
accordance with certain embodiments of the present disclosure. In
certain embodiments, second end 230 may be a wider end of bale arm
200 compared to first end 220. As discussed with respect to FIG.
2A, second end 230 may comprise one or more side portions 232. In
certain embodiments, second end 230 may comprise a first side
portion 232a and a second side portion 232b. second end 230 may
further comprise a bottom bar 235 disposed substantially
horizontally in between side portions 232. Side portions 232 may be
substantially vertical such that bottom bar 235 is substantially
perpendicular to side portions 232. Bottom bar 235 may be coupled
to side portions 232 via arcuate portions 238. Similar to arcuate
portions 228, arcuate portions 238 may provide substantially
perpendicular angles between side portions 232 and bottom bar 235.
In certain embodiments, the length L.sub.6 of second end 230 may be
approximately 4.25 inches, and the length L.sub.7 of bottom bar 235
of second end 230 may be approximately 3.25 inches.
[0073] Thus, in certain embodiments, second end 230 may be a wide
end a first end 220 may be a narrow end, such that the second end
230 is wider than the first end 220. Furthermore, because first end
220 may be angled 105 degrees away from swing bar 210, a first end
220 may be configured to interlock with a second end 230, as
described in more detail with respect to FIG. 3.
[0074] FIG. 2D is a rear view of bale arm 200 in accordance with
certain embodiments of the present disclosure. From the rear view,
swing bar 210 of bale arm 200 may be partially or substantially
below the top of rear panel 130 of tote 100, such that swing bar
210 is not visible. Thus, in certain embodiments, only first end
220 and second end 230 of bale arm 200 may be visible from the rear
view. As depicted in FIG. 2D, first end 220 may comprise a top bar
221 and a side bar 222. First end 220 may further comprise an
arcuate portion 224 providing a substantially perpendicular angle
between top bar 221 and side bar 222. In certain embodiments, side
bar 222 may be approximately 1.2 inches and top bar 221 may be
approximately 2 inches. Similarly, second end 230 may comprise a
top bar 231 and a side bar 232. Second end 230 may further comprise
an arcuate portion 234 for providing a substantially perpendicular
angle between top bar 231 and side bar 232. In certain embodiments,
the visible portions of second end 230 and first end 220 may be
roughly equal. For example, in certain embodiments, side bar 232
may be approximately 1.2 inches and top bar 231 may be
approximately 2 inches.
[0075] In certain embodiments, the unformed wire length of bale arm
200 may be approximately 35 inches and may weigh approximately 0.5
pounds. As would be understood by one of ordinary skill in the art,
the weight and overall wire length of bale arm 200 may be varied
according to the needs of the tote 100.
[0076] FIG. 3A depicts a side-by-side tote configuration with
pre-interlocking bale arms in accordance with certain embodiments
of the present disclosure. For example, as shown in FIG. 3A, a
first tote 100a may be placed or disposed substantially adjacent to
and aligned with a second tote 100b. In certain embodiments, a
first tote 100a and a second tote 100b may be positioned such that
a first bale arm 200a of first tote 100a is substantially aligned
with a first bale arm 200a of a second tote 100b, and a second bale
arm 200b of first tote 100a is substantially aligned with second
bale arm 200b of second tote 100b. More specifically, the first end
220 of first bale arm 200a of the first tote 100a is substantially
aligned with the second end 230 of first bale arm 200a of the
second tote 100b. Further, the second end 230 of second bale arm
200b of first tote 100a is substantially aligned with the first end
220 of second bale arm 200b of second tote 100b.
[0077] FIG. 3B depicts a side-by-side tote configuration with
interlocking bale arms in accordance with certain embodiments of
the present disclosure. For example, as shown in FIG. 3B, a first
tote 100a may be placed or disposed sufficiently close to a second
tote 100b such that the first end 220 of first bale arm 200a of the
first tote 100a overlaps and interlocks with the second end 230 of
first bale arm 200a of the second tote 100b. More specifically, for
example, the first end 220 of first bale arm 200a of first tote
100a may be threaded through the second end 230 of first bale arm
200a of second tote 100b, such that at least a portion of first end
220 of first bale arm 200a of first tote 100a is positioned in
between side panel 125a of second tote 100b and at least a portion
of second end 230 of first bale arm 200a of second tote 100b.
Similarly, in the interlocked position, at least a portion of
second end 230 of first bale arm 100a of second tote 100b may be
positioned between side panel 125b of first tote 100a and at least
a portion of first end 220 of first bale arm 200a of first tote
100a.
[0078] In a similar manner, as shown in FIG. 3B, the second end 230
of second bale arm 200b of first tote 100a may overlap and
interlock with the first end 220 of second bale arm 200b of second
tote 100b. More specifically, for example, the first end 220 of
second bale arm 200b of second tote 100b may be threaded through
the second end 230 of second bale arm 200b of first tote 100a, such
that at least a portion of first end 220 of second bale arm 200b of
second tote 100b is positioned between side panel 125b of first
tote 100a and at least a portion of second end 230 of second bale
arm 200b of first tote 100a. Similarly, in the interlocked
position, at least a portion of second end 230 of second bale arm
200b of first tote 100a may be positioned between side panel 125a
of second tote 100b and at least a portion of first end 220 of
second bale arm 200b of second tote 100b. As would be understood by
one of ordinary skill in the art, the interlocking of bale arms 200
between one or more totes 100 may be implemented in other ways, in
keeping with aspects of the present disclosure.
[0079] FIG. 4 depicts a stacked tote configuration 400 of one or
more totes 100, for example, a first tote 100a stacked on top of a
second tote 100b, in accordance with certain aspects of the present
disclosure. First tote 100a may be stacked on second tote 100b by
placing the bottom panel 120 of tote 100a on bale arms 200 of the
tote 100b directly below it. First tote 100a may be stacked on
second tote 100b such that the bottom panel 120 of tote 100a fits
on the swing bars 210 (not visible) of bale arms 200 of second tote
100b and fits snugly within the side panels 125, front panel 135,
and rear panel 130 of second tote 100b. The stacked configuration
400 may provide for increased stability of both totes 100a and
100b.
[0080] In general, the stacked configuration 400 of one or more
totes 100 may provide for increased stability of the one or more
totes 100, for example, in a tote system 500 as described below
with respect to FIG. 5. For example, in a busy warehouse or other
retail staging area for fulfilment of pick-up orders, a tote 100
may be knocked over inadvertently by an employee or by a machine,
causing delays in the fulfillment of retail orders. The stackable
nature of the one or more totes 100 may reduce the likelihood that
a tote will be knocked over or displaced, thus, improving the
efficiency of fulfilling retail pick-up orders. Additionally, the
stackable nature of one or more totes 100 may reduce the footprint
required for the staging and storage of goods in a warehouse or
staging area for retail fulfillment of pick-up orders. With the
increased popularity of curbside pick-up and other types of
customer pick-up orders, space in staging areas can be at a
premium. The stackable nature of one or more totes 100 may allow
for efficient use of floor space in a staging area, allowing for
more orders to be processed and prepared in a shorter amount of
time.
[0081] FIG. 5 depicts a tote system 500 in accordance with certain
embodiments of the present disclosure. In certain embodiments, tote
system 500 may comprise one or more totes 100, for example, totes
100a, 100b, 100c, 100d, 100e, 100f, 100g, 100h, 100i, 100j, 100k,
1001, 100m, 100n, 100o, 100p, 100q, and 100r. As would be
understood by one of ordinary skill in the art, any number of totes
100, for example, totes 100a, 100b, 100c, . . . 100z, may be used
in accordance with aspects of the present disclosure. In certain
embodiments, tote system 500 may comprise 18 totes 100 in a
6.times.3 configuration as depicted in FIG. 5. For example, as
shown in FIG. 5, tote system 500 may comprise three columns 510
each comprising six stacked totes 100. However, in certain
embodiments, other tote configurations may be appropriate. For
example, a tote system 500 may comprise 4 totes in a 2.times.2
configuration, 12 totes in a 3.times.4 configuration, or 25 totes
in a 5.times.5 configuration. As would be understood by one of
ordinary skill in the art, any number of suitable configurations
may be selected based on a variety of factors, for example, the
number of retail orders and the number of totes needed per retail
order.
[0082] Each tote 100 may be stacked on one another by placing the
bottom panel 120 of each tote 100 on bale arms 200 of the tote 100
directly below it, as described above with respect to FIG. 4. For
example, tote 100a may be stacked on tote 100b by placing the
bottom panel 120 of tote 100a on the swing bars 210 of bale arms
200 of tote 100b. Totes 100, for example, totes 100a, 100b, 100c,
100d, 100e, and 100f, may be stacked on top of one another such
that there are, for example, six totes 100 stacked in a single
column 310, of totes 100, for example in a first column 510a.
Furthermore, as depicted in FIG. 3, totes 100g, 100h, 100i, 100j,
100k, and 1001 may be stacked on top of one another in a second
column 510b, and totes 100m, 100n, 100o, 100p, 100q, and 100r may
be stacked on top of one another in a third column 510c.
[0083] In certain embodiments, three columns 510 may be placed
side-by-side with an equal number of totes 100 in each column 510.
For example, columns 510a, 510b, and 510c each comprising six totes
100 may be placed side-by-side. In certain embodiments, columns
510a, 510b, and 510c may be placed sufficiently close to each other
that totes 100 may interlock one or more adjacent totes 100. For
example, first column 510a and second column 510b may be positioned
sufficiently close together so that the totes 100a, 100b, 100c,
100d, 100e, and 100f of first column 510a are substantially aligned
with totes 100g, 100h, 100i, 100j, 100k, and 1001 of second column
510b. Furthermore, each tote 100 of column 510a may interlock with
each corresponding tote 100 of column 510b. For example, tote 100a
may interlock with tote 100g by way of first end 220 of tote 101g
overlapped or interlocked with second end 230 of tote 101a, as
shown more clearly in FIGS. 3A and 3B. Thus, any movement or
displacement of tote 100a may be suppressed by the interlocking
arms of tote 100g. Similarly, movement of any totes 100 in first
column 510a may be suppressed by the interlocking arms of the
corresponding totes in second column 510b. The interlocking
configuration of totes 100 in column 510a with totes 100 in column
510b may provide for increased stability of the tote system
500.
[0084] Similarly, a third column 510c may be positioned and aligned
with second column 510b (and thus, also aligned with first column
510a) such that totes 100m, 100n, 100o, 100p, 100q, and 100r of
third column 510c are substantially aligned totes 101g, 100h, 100i,
100j, 100k, and 1001 of second column 510b. Furthermore, each tote
100 of third column 510c may also interlock with each corresponding
and adjacent tote 100 of second column 510b. For example, tote 100m
may interlock with 100g by way of second end 230 of tote 100m
overlapped with first end 220 of tote 101g, as shown more clearly
in FIGS. 3A and 3B. Thus, any movement or displacement of tote 100g
may be suppressed by the interlocking arms of tote 100m. Similarly,
movement of any totes 100 in column 510b may be suppressed by the
interlocking arms of the corresponding totes in column 510c. The
interlocking configuration of totes 100 in column 510a with totes
100 in column 510b may provide for increased stability of the tote
system 500.
[0085] The stackable and modular nature of one or more totes 100
may allow retail orders to be organized more efficiently and
grouped together for faster retrieval. For example, one or more
retail orders may be stored in one or more totes 100. The one or
more totes 100 corresponding to a given retail order may be grouped
in the same stack, for example, column 510a. Thus, an operator may
be able to quickly identify the retail items for a given order
based on the grouping of totes 100. As would be understood by one
of ordinary skill in the art, a different grouping of totes 100 may
correspond to a given retail order, for example, a row of totes
100. For example, based on one or more factors such as the size or
number of items in a retail order, totes 100a, 100g, and 100m may
correspond to a retail order. In certain embodiments, the entire
tote system 500 may correspond to a retail order.
[0086] As would be understood by one of ordinary skill in the art,
any number of tote systems 500 may be used in accordance with
aspects of the present disclosure. For example, a warehouse or
retail order fulfillment area may comprise 1, 5, 10, 20, or 50 tote
systems 500. Furthermore, in certain embodiments, one or more tote
systems 500 may each be placed on a pallet 550 for easy of
transport such that an operator may be able to move the one or more
tote systems 500 efficiently using a fork lift or other machinery.
In certain embodiments, one or more tote systems 500 may fit on a
single pallet 550. In certain embodiments, a pallet 550 may be 40''
wide by 48'' long. In certain embodiments, pallet 550 may allow two
tote systems 500 or 36 totes 100 to fit thereon (not shown). The
stackable and modular nature of totes 100 may provide flexibility
in both the number of totes 100 in a given tote system 500, as well
as the number of totes 100 on a pallet 550.
[0087] FIG. 6 depicts a side-by-side tote configuration 600 with
interlocking bale arms in accordance with certain embodiments of
the present disclosure. Similar to FIG. 3B, totes 100a and 100b may
be placed or disposed sufficiently close together such that the
first end 220 of bale arm 200 of a first tote 100a overlaps and
interlocks with second end 230 of bale arm 200 of the second tote
100b. However, in certain embodiments, bale arms 200 of both totes
100 may be rotated such that each bale arm 200 is substantially in
front of and to the rear of tote 100, rather than across the top of
tote 100. For example, as shown in FIG. 6, a first bale arm 200a
may be rotated (e.g., 90 degrees) such that the first bale arm 200a
sits across front panel 135 of tote 100, and a second bale arm 200b
may be rotated such that the second bale arm 200b sits across rear
panel 130 of tote 100 (shown more clearly in FIG. 7). As described
below in more detail with respect to FIG. 7, rotation of the bale
arms 200 may allow for a "nested" configuration when retail goods
are not being stored or held in the totes 100.
[0088] FIG. 7 depicts a nested configuration 700 of one or more
totes 100, for example, totes 100a, 100b, 100c, 100d, and 100e, in
accordance with certain aspects of the present disclosure. In
certain embodiments, a "nested" configuration may be useful when
the totes 100 are empty or otherwise not being used for storing or
staging retail items for pickup. For example, a nested
configuration of one or more totes 100 may be used when there is a
surplus of totes 100 needed for fulfilling retail orders at a given
time. Storing one or more totes 100 in a nested configuration may
retain valuable space in a warehouse, staging area, or other retail
space.
[0089] As described above, the trapezoidal shape of totes 100 may
in certain embodiments, allow a first tote 100a to be nestable in a
second tote 100b, such that the bottom panel 120 of the first tote
100a sits within the second tote 100b. One or more totes 100 may be
nested within one another in accordance with one or more aspects of
the present disclosure. For example, as shown in FIG. 7, 100a may
be nested in tote 100b, tote 100b may be nested in 100c, tote 100c
may be nested in 100d, and tote 100d may be nested in 100e. In
certain embodiments, the distance between bottom panels 120 of
respective totes 100 may be approximately 5 inches or less in a
nested configuration. However, as would be understood by one of
ordinary skill in the art, the distance between totes may vary
based on the size and dimensions of totes 100. The number of
nestable totes 100 may vary based on one or more factors, for
example, the amount of available space in a retail fulfillment
area, the number of retail orders needed to be fulfilled, the
number of retail items needed to be staged, etc. In certain
embodiments, any number of nested totes may be appropriate, for
example, 5, 10, 15, or 20 totes 100 may be nested. In certain
embodiments, the nestable totes 100 may be placed on a pallet 550
(not shown) for easy transport by a fork lift or other
machinery.
[0090] FIG. 8 depicts a tote 800 in accordance with certain
embodiments of the present disclosure. Similar to tote 100, tote
800 may comprise a plastic material, such as any type of plastic
listed above. In certain embodiments, tote 800 may comprise a
molded plastic. In certain embodiments, molded plastic may be
preferable to corrugated plastic because molded plastic may be
easier to clean, due to the flat surface of molded plastic. Tote
800 may have similar dimensions to tote 100, and may comprise a
substantially trapezoidal shape. For example, as shown more clearly
in FIG. 8C, in certain embodiments, tote 800 may have a length
L.sub.t along the top edge of the tote 800 of approximately 14
inches and a length L.sub.b along a bottom edge of the tote 800 may
be approximately 11 inches. Further, as shown more clearly in FIG.
8B, tote 800 may have a width W.sub.t along a top edge of the tote
800 of approximately 23 inches and a width W.sub.b along a bottom
edge of the tote 800 of approximately 20 inches. Tote 800 may have
a height H of approximately 11 inches and a bottom thickness T of
approximately 1 inch. As discussed above, any one or more of these
dimensions may be varied or selected based on one or more factors,
for example, the size, weight, shape, or type of retail goods to be
stored, in keeping with aspects of the present disclosure.
[0091] As shown in FIG. 8A, similar to tote 100, tote 800 may
comprise a bottom panel 820, side panels 825a and 825b, rear panel
830, and front panel 835, which may substantially comprise and
opening or window 837 for inserting and removing goods from tote
800. In certain embodiments, tote 800 may comprise one or more hand
holds 840, each aligned along the top edge of side panels 825. In
certain embodiments, hand holds 840 may be replaced by other handle
designs, for example, a handle that that protrudes from the side
panels 825 (not shown), rather than an opening like the hand holds
840 shown in FIG. 8A. For example, handles of tote 800 may comprise
one or more surfaces, edges, or additional material, e.g.,
corrugated plastic, protruding from the side panels 825 (not
shown). The bottom edge of the handles may be straight, curved, or
rounded for ease of handling (not shown). As would be understood by
one of ordinary skill in the art, as discussed above with regard to
tote 100, various types of handle designs may be used with tote 800
and may be selected based on one or more factors, for example,
ergonomic considerations when lifting heavy totes or storage space
requirements of various handle options.
[0092] As shown in FIG. 8A, tote 800 may further comprise a lid
850. Lid 850 may comprise a first lid panel 851a and a second lid
panel 851b. In certain embodiments, lid panels 851 may comprise one
or more key connectors 855 for facilitating the coupling of lid
panels 851 to one another, for example, first lid panel 851a to
second lid panel 851b. In certain embodiments, first lid panel 851a
may comprise key connectors 855 and second panel 851b may comprise
key openings 855b. Key connectors 855 may couple to key slots 856
to attach first lid panel 851a to second lid panel 851b. As would
be understood by one of ordinary skill in the art, key connectors
855 and key slots 856 may have other shapes or structures, e.g.,
circular or elliptical shapes rather than rectangular, such that
key connectors 855 and key slots 856 couple to one another. In
certain embodiments, lid 850 may only comprise a single lid panel
851 and may not comprise any key connectors 855 or key slots 856
(not shown). In certain embodiments, lid 850 may be attached or
coupled to tote 800 via one or more hinges 852. For example, one or
more hinges 852 may be aligned across a top edge of side panels 825
for coupling the lid 850 or lid panels 851 to the tote 800. In
certain embodiments, lid 850 may be configured in an open or closed
position. For example, lid 850 may be in a closed position when it
is desirable to stack one or more totes 800 on top of one another,
for example, like shown in FIGS. 4 and 5. Lid 850 may be in an open
position when it is desirable to nest one or more totes 800 in one
another, for example, like shown in FIG. 7.
[0093] In certain embodiments, lid 850 may further comprise one or
more openings 857. Openings 857 may correspond to and align with
one or more protrusions 827 on side panels 825 when lid 850 is
moved to an open position, such that lid 850 may couple to or
attach to side panels 825. In an open position, openings 857 and
protrusion 827 may secure lid 850 to one or more side panels 825
such that lid 850 is not displaced or otherwise obstructive to an
operator when the tote 800 is in transport. Additionally, openings
857 and protrusions 827 may keep lid 850 from fanning out while one
or more totes 800 are in a nested configuration (not shown), i.e.,
so that the lid 850 does not become an obstruction when nesting the
totes 800 within one another. As would be understood by one of
ordinary skill in the art, openings 857 on lid 850 and protrusions
827 on side panel 825 may take other shapes, for example, circular,
oval, or rectangular (not shown) such that lid 850 may be coupled
to and secured against side panel 825. Additionally, protrusion 827
may serve as a "nest stop" such that a tote 800 is prevented from
sliding all the way within another tote 800. For example, in a
nested configuration, the bottom edges of protrusion 827 of a first
tote 800 may come into contact with the top edge of side panel 825
of a second tote 800 such that the first tote 800 cannot nest any
further into the second tote 800 (not shown).
[0094] Lid 850 may further comprise one or more key connectors 860
as shown in FIG. 8A, for example key connectors 860a and 860b. In
certain embodiments, key connectors 857 may be structurally
similarly to key connectors 855 of lid 850. Rather than couple to
key slots 856 of lid 850, however, key connectors 857 may be used
to couple to one or more key slots 856 of bottom panel 820, as
shown more clearly in FIG. 8D. Coupling one or more key connectors
855 on lid 850 to one or more key slots 856 on bottom panel 820 may
provide increased stability and structural support when one or more
totes 800 are in a stacked configuration (not shown). In certain
embodiments, four key connectors 855 may be located near the
corners of lid 850, and four key slots 856 may be located near the
corners of bottom panel 820 (not shown). However, as would be
understood by one of ordinary skill in the art, any number of key
connectors 855 and key slots 856 may be used and in a variety of
configurations to stack one or more totes 800 on top of one another
while providing the desired structural stability. Bottom panel 820
may further comprise one or more grooves 880 on the bottom surface
of bottom panel 820 to provide improved friction along bottom panel
820. For example, in certain embodiments, tote 800 may be placed on
a moving conveyor (not shown) for transporting tote 800 to or from
a location, e.g., a fulfillment center.
[0095] Tote 800 may further comprise a bale arm 875. In certain
embodiments, tote 800 may comprise two or more bale arms 875 (not
shown). In certain embodiments, as shown in FIG. 8A, it may only be
necessary to have a single bale arm 875 because lid 850 may be
positioned on top of bale arm 875 and rear panel 830 in a closed
position. Bale arm 875 may be partially enclosed within the body of
tote 800. For example, the ends of bale arm 875 may be molded
within the plastic of the tote 800. In certain embodiments, bale
arm 875 may be positioned adjacent to or aligned against front
panel 835 without any gap such that bale arm 875 does not obstruct
another tote 800 from being nested within the tote 800 when the lid
850 is in an open position (not shown).
[0096] FIG. 9 depicts a tote 900 in accordance with certain
embodiments of the present disclosure. Similar to totes 100 and 800
as discussed above, tote 900 may comprise a plastic material, such
as corrugated plastic, or for example, other types of plastic
listed above. Tote 900 may similarly comprise a substantially
trapezoidal shape and may have similar dimensions to totes 100 and
800. For example, as shown more clearly in FIG. 9C, in certain
embodiments, tote 900 may have a length L.sub.t along the top edge
of the tote 900 of approximately 23 inches and a length L.sub.b
along a bottom edge of the tote 900 may be approximately 21 inches.
Further, as shown more clearly in FIG. 9B, tote 900 may have a
width W.sub.t along a top edge of the tote 900 of approximately 14
inches and a width W.sub.b along a bottom edge of the tote 900 of
approximately 11 inches. Tote 800 may have a height H of
approximately 12 inches and a bottom thickness T of approximately 1
inch. As discussed above, any one or more of these dimensions may
be varied or selected based on one or more factors, for example,
the size, weight, shape, or type of retail goods to be stored, in
keeping with aspects of the present disclosure.
[0097] As shown in FIG. 9A, similar to totes 100 and 800, tote 900
may comprise a bottom panel 920, side panels 925a and 925b, rear
panel 930, and front panel 935, which may substantially comprise
and opening or window 937 for inserting and removing goods from
tote 900. In certain embodiments, tote 900 may comprise one or more
hand holds 940, each aligned along the top edge of side panels 925.
In certain embodiments, hand holds 940 may be replaced by other
handle designs, for example, a handle that that protrudes from the
side panels 925 (not shown), rather than an opening like the hand
holds 940 shown in FIG. 9A. For example, handles of tote 900 may
comprise one or more surfaces, edges, or additional material, e.g.,
corrugated plastic, protruding from the side panels 925 (not
shown). The bottom edge of the handles may be straight, curved, or
rounded for ease of handling (not shown).
[0098] Tote 900 may further comprise one or more bale arms 975, for
example, bale arms 975a and 975b. In certain embodiments, bale arms
975 may be molded within the molded plastic of tote 900 such that
it is secured to and part of the tote 900. Similar to bale arms 200
discussed above with respect to tote 100, bale arms 975 of tote 900
may swivel or rotate between a first position and a second
position. In certain embodiments, bale arms 975 in a first position
may represent a stackable position, such that another tote 900 may
be placed or stacked on top of bale arms 975. Tote 900 may further
comprise one or more slots 927, for example, slots 927a, 927b,
927c, and 927d, along a top edge of side panels 925 to receive bale
arms 975 in a stackable position. In certain embodiments, bale arms
975 in a second position may represent a nestable position, such
that the bale arms 975 do not obstruct another tote 900 to be
nested within another tote 900.
[0099] One or more totes 900 may be positioned in a stacked
configuration, similar to totes 100 as shown in FIGS. 4 and 5.
However, bale arms 975 of tote 900 may not have the interlocking
feature, as shown most clearly in FIGS. 3 and 5, as tote 100. The
lack of interlocking bale arms 975 in a stacked configuration may
provide time gains when re-positioning or retrieving down-stacked
totes for fulfillment. In certain embodiments, bale arms 975 may be
used with tote 100 and bale arms 200 may be used with tote 900. As
would be understood by one of ordinary skill in the art, when
selecting the more appropriate bale arm 200 or 975, the benefits of
the improved structural stability provided by the interlocking
feature of bale arm 200 should be weighed against the benefits of
efficiency in positioning and re-positioning totes 100 or 900 with
bale arms 975 that do not have an interlocking feature.
[0100] FIG. 9D shows tote 900 with second bale arm 975b in a
nestable position. In a nestable position, bale arm 975 may be
coupled to one or more latches 980, for example latch 980a and
980b. In certain embodiments, latches 980 may be molded as part of
the molded plastic of tote 900. In other embodiments, latches 980
may be coupled to rear panel 930, for example, via an adhesive.
Latches 980 may secure one or more bale arms, for example, bale arm
975b against the rear panel 930 of tote 900 such that bale arm 975b
does not fan out or otherwise obstruct another tote 900 (not shown)
from being nested within the tote 900. In certain embodiments, in a
nestable position of tote 900, first bale arm 975a may be
positioned on top of and flush with front panel 935 (not shown)
such that bale arm 975a does not fan out when nested or obstruct
another tote 900 (not shown) from being nested within the tote
900.
[0101] In certain embodiments, tote 900 may further comprise one or
more nest stops 955, for example, nest stops 955a and 955c shown in
FIG. 9A. In certain embodiments, nest stops 955 may be molded as
part of the molded plastic of tote 900. In other embodiments, nest
stops 955 may be coupled to the tote 900, for example, via an
adhesive. One or more nest stops 955 may prevent a tote 900 from
sliding all the way within another tote 900 in a nested
configuration (not shown). For example, in a nested configuration,
the bottom edges of nest stops 955 of a first tote 900 may come
into contact with the top edge of side panel 925 of a second tote
900 such that the first tote 900 cannot nest any further into the
second tote 900 (not shown). Additionally, the bottom edges of
latches 980 may also serve as nest stops in a similar manner.
[0102] Therefore, the present disclosure is well adapted to attain
the ends and advantages mentioned, as well as those that are
inherent therein. The particular embodiments disclosed above are
illustrative only, as the present disclosure may be modified and
practiced in different but equivalent manners apparent to those
skilled in the art having the benefit of the teachings herein.
Furthermore, no limitations are intended to the details of
construction or design herein shown, other than as described in the
claims below. It is therefore evident that the particular
illustrative embodiments disclosed above may be altered or modified
and all such variations are considered within the scope and spirit
of the present disclosure. While compositions and methods are
described in terms of "comprising," "containing," or "including"
various components or steps, the compositions and methods can also
"consist essentially of" or "consist of" the various components and
steps. All numbers and ranges disclosed above may vary by some
amount. Whenever a numerical range with a lower limit and an upper
limit is disclosed, any number and any included range falling
within the range is specifically disclosed. In particular, every
range of values (of the form, "from about a to about b," or,
equivalently, "from approximately a to b," or, equivalently, "from
approximately a-b") disclosed herein is to be understood to set
forth every number and range encompassed within the broader range
of values. Also, the terms in the claims have their plain, ordinary
meaning unless otherwise explicitly and clearly defined by the
patentee. Moreover, the indefinite articles "a" or "an," as used in
the claims, are defined herein to mean one or more than one of the
element that it introduces. If there is any conflict in the usages
of a word or term in this specification and one or more patent or
other documents that may be incorporated herein by reference, the
definitions that are consistent with this specification should be
adopted.
* * * * *