Delivery tote with lid

Abstract

A nestable tote includes a base with product retention features protruding from an upper surface to define recesses for retaining items, such as jars, without interfering with nesting of identical totes. Variations include ribs, cross-ribs, segmented ribs, flexible straps, interlocking dividers, or grids with diamond intersections. A system includes the tote and a lid with a recess for stacking, configured to center the tote on an ASRS tray to prevent misalignment. Another system includes a pallet assembly with a top deck having recesses to securely receive totes or lidded totes, enabling multi-layer stacking. A method involves placing totes in the pallet recesses and transporting via pallet handling equipment.

Description

BACKGROUND

[0001] Stackable and nestable totes are known for storing and transporting items. Some totes are configured to stack on identical totes in one orientation and nest within identical totes when rotated 180 degrees. When used in an automated storage retrieval system (ASRS), these totes may misalign on trays, leading to instability or protrusion beyond the tray footprint during automated handling. Additionally, smaller items, such as a few jars or cans, may not be secured within the much larger tote.SUMMARY

[0002] A nestable tote includes a base having a bottom surface and an upper surface. Opposing side walls extend upward from side edges of the base, and opposing end walls extend upward from end edges of the base. A plurality of product retention features protrude upward from the upper surface of the base to define a plurality of product retention recesses configured to retain items therein. The product retention features are dimensioned to permit an identical tote to nest therein without a base of the identical tote contacting the product retention features. The bottom surface of the base may be substantially smooth for use with ASRS.

[0003] The product retention features may include a grid of ribs protruding upward from the upper surface of the base. Short product retention cross-ribs may be formed perpendicularly to the ribs, configured to abut the items in the product retention recesses. The heights of the short product retention cross-ribs may be tapered toward the upper surface of the base at free ends thereof.

[0004] Alternatively, the product retention features may include product retention ribs extending at least partially circumferentially about each of the product retention recesses. The product retention ribs may be segmented.

[0005] The product retention features may include flexible straps removably secured to at least one of the side walls or end walls, defining at least portions of the product retention recesses. Each flexible strap may include clips at ends thereof configured to engage slots in the side walls or end walls, or fasteners configured to pass through slots in the side walls or end walls and connect on an exterior thereof. The flexible straps may be removable and configured to lay flat on the upper surface of the base when not in use.

[0006] The product retention features may include interlocking dividers insertable onto the upper surface of the base, defining the product retention recesses. The dividers may be disengageable and configured to lay flat on the upper surface of the base when not in use.

[0007] The product retention features may include short product retention ribs that do not completely encircle the product retention recesses and partially define multiple product retention recesses.

[0008] The product retention features may include a grid of reinforcing ribs with curved portions to round off corners, and short product retention ribs cooperating therewith to define the product retention recesses.

[0009] The product retention features may include ribs formed in a grid with diamond-shaped intersections configured to provide a snug fit for the items.

[0010] A system includes the nestable tote and a lid securable to upper edges of the side walls and end walls. The lid includes an upper recess configured to receive a base of an identical tote for stacking. The system may further include a tray having a base with ribs and peripheral retention fingers, wherein the lid is configured to fit between the retention fingers and center the nestable tote on the tray such that upper edges of the nestable tote do not protrude beyond a footprint of the tray.

[0011] A system includes the nestable tote and a pallet assembly including a pallet and a top deck secured thereto. The top deck has at least one recess configured to receive the base of the nestable tote for secure positioning. The top deck may include a plurality of recesses, each configured to receive one of a plurality of nestable totes. The system may further include a lid securable to the nestable tote, wherein the recess of the top deck is configured to receive the nestable tote with the lid attached. Alternatively, the plurality of recesses may be integrally molded into the upper surface of the pallet.

[0012] A pallet assembly includes a pallet having a deck and a plurality of feet projecting downward from the deck to support the deck above a floor. A top deck is secured to an upper surface of the deck of the pallet. The top deck includes an upper surface having at least one recess formed therein. The at least one recess has a perimeter configured to receive a base of a tote. The at least one recess includes a pair of adjacent supporting surfaces at each corner thereof configured to receive outer columns of the tote in either of two 180-degree rotated orientations. The at least one recess further includes coves along side edges thereof configured to receive central columns of the tote. The top deck may include a plurality of recesses, each configured to receive one of a plurality of totes. The top deck may include openings aligned with the feet of the pallet, the openings configured to receive feet of an identical pallet assembly stacked thereon. Alternatively, the plurality of recesses may be integrally molded into the upper surface of the deck of the pallet.

[0013] A method of transporting totes includes placing at least one tote into at least one recess formed in an upper surface of a top deck of a pallet assembly. The pallet assembly includes a pallet having a deck and a plurality of feet projecting downward from the deck, with the top deck secured to an upper surface of the deck of the pallet. The at least one recess has a perimeter receiving a base of the at least one tote and includes a pair of adjacent supporting surfaces at each corner thereof receiving outer columns of the at least one tote in one of two 180-degree rotated orientations. The at least one recess further includes coves along side edges thereof receiving central columns of the at least one tote. The method further includes moving the pallet assembly with the at least one tote secured therein using pallet handling equipment. The method may further include stacking a plurality of layers of additional totes on the at least one tote in the at least one recess. The method may further include securing a lid to the at least one tote prior to placing the at least one tote into the at least one recess, wherein the lid is received in the at least one recess.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a perspective view of a tote according to a first embodiment.

[0015] FIG. 2 shows the tote of FIG. 1 with an identical, upper tote stacked thereon.

[0016] FIG. 3 shows the upper tote nested in the tote of FIG. 1.

[0017] FIG. 4 shows the tote of FIG. 1 with a lid on the upper edges of the side walls and end walls.

[0018] FIG. 5 shows the tote and lid of FIG. 4 with the identical tote stacked thereon.

[0019] FIG. 6 shows a tray that is currently used in an existing automated storage and retrieval system (ASRS).

[0020] FIG. 7 shows the lid of FIG. 4 received in the tray.

[0021] FIG. 8 shows the tote of FIG. 1 received in the recess of the lid on the tray of FIG. 7.

[0022] FIG. 9 is an end view of the tote, lid, and tray of FIG. 8.

[0023] FIG. 10 is a side view of the tote, lid, and tray of FIG. 8.

[0024] FIG. 11 is a top view of a tote according to a second embodiment.

[0025] FIG. 12 is a section view taken along line A-A of FIG. 11.

[0026] FIG. 13A is an upper perspective view of a tote according to a third embodiment with four jars received therein.

[0027] FIG. 13B is a perspective view of the interior of the tote of FIG. 13A, partially broken away.

[0028] FIG. 13C is a section view through the tote of FIG. 13A with an identical tote nested therein.

[0029] FIG. 14A is an upper perspective view of a tote according to a fourth embodiment.

[0030] FIG. 14B is a perspective view of the interior of the tote, partially broken away.

[0031] FIG. 14C is a section view through the tote of FIG. 14A with an identical tote nested therein.

[0032] FIG. 15A is an upper perspective view of a tote according to a fifth embodiment.

[0033] FIG. 15B is a perspective view of one of the flexible product retention straps of FIG. 15A.

[0034] FIG. 15C is a perspective view of the interior of the tote of FIG. 15A, partially broken away.

[0035] FIG. 15D is a section view through the tote of FIG. 15A with an identical tote nested therein.

[0036] FIG. 15E is an upper perspective view of the tote of FIG. 15A with the flexible product retention straps removed from the slots and laid flat on the upper surface of the base.

[0037] FIG. 16A is an upper perspective view of a tote according to a sixth embodiment with jars secured therein.

[0038] FIG. 16B is a perspective view of the interior of the tote of FIG. 16A, partially broken away.

[0039] FIG. 16C is an exterior view of the tote of FIG. 16A.

[0040] FIG. 16D is a section view through the tote of FIG. 16A with an identical tote nested therein.

[0041] FIG. 17A is a perspective view of a tote according to a seventh embodiment with several jars secured therein.

[0042] FIG. 17B shows the dividers being inserted into the tote of FIG. 17A.

[0043] FIG. 17C is an exploded perspective view of the dividers of FIG. 17A.

[0044] FIG. 17D is a section view through the tote of FIG. 17A with an identical tote nested therein.

[0045] FIG. 18 is a top view of a tote according to an eighth embodiment.

[0046] FIG. 19 is a top view of a tote according to a ninth embodiment.

[0047] FIG. 20 is a top view of a tote according to a tenth embodiment.

[0048] FIG. 21 is a top view of a tote according to an eleventh embodiment.

[0049] FIG. 22 is an upper perspective view of the tote of FIG. 21.

[0050] FIG. 23 is a perspective view of a pallet assembly that can be used with all of the preceding totes.

[0051] FIG. 24 is an exploded perspective view of the pallet assembly of FIG. 23.

[0052] FIG. 25 is a top view of the top deck of FIG. 23.

[0053] FIG. 26 is a perspective view of the pallet assembly of FIG. 23 with three of the totes thereon.

[0054] FIG. 27 shows the pallet assembly and totes of FIG. 26 with additional layers of totes stacked thereon.

[0055] FIG. 28 is a perspective view of one tote with a lid interlocked with one of the recesses of the pallet assembly of FIG. 23.

[0056] FIG. 29 is a perspective view of three totes with lids each interlocked with one of the recesses of a pallet assembly of FIG. 23.

[0057] FIG. 30 is an end view of the totes and pallet assembly of FIG. 29.

[0058] FIG. 31 is a side view of the totes and pallet assembly of FIG. 29.

[0059] FIG. 32 is a perspective view of a plurality of layers of totes with lids stacked on the pallet assembly of FIG. 29.

[0060] FIG. 33 is a perspective view of the pallet assembly of FIG. 23 with an identical pallet assembly stacked thereon.

[0061] FIG. 34 is an end view of the pallet assemblies of FIG. 33.DETAILED DESCRIPTION

[0062] A tote 10 according to a first embodiment is shown in FIG. 1. The tote 10 is a 180 stack / nest tote, i.e. the tote 10 will stack on an identical tote in one orientation and will nest in the identical tote when rotated 180 degrees. The tote 10 includes a base 12, side walls 14 extending upward from side edges of the base 12, and end walls 16 extending upward from end edges of the base 12. Handle openings 18 are formed through each of the end walls 16. A lip 19 projects outward from the upper edge of the side walls 14 and end walls 16. The base 12, side walls 14, and end walls 16 are integrally molded as a single piece of plastic.

[0063] Each side wall 14 includes a pair of inner columns 22. Each inner column 22 is adjacent an inner channel 20 that also forms an outer column 23 on an exterior of the side wall 14. Stacking surfaces 24 are defined at the upper ends of each of the inner columns 22. In this example, the stacking surfaces 24 are recessed. Each side wall 14 includes a large central column 26 between the inner columns 22 or between the outer columns 23.

[0064] In this example, the inner columns 22 on one side wall 14 are spaced closer to one another than on the other side wall 14, while the inner channels 20 on the one side wall 14 are spaced further from one another than the other side wall 14. This is one way of implementing the 180 stack nest function. Other configurations are also known.

[0065] FIG. 2 shows the tote 10 of FIG. 1 with an identical, upper tote 10 stacked thereon. The upper tote 10 is rotated 180 degrees relative to the lower tote 10. This positions the outer column 23 of the upper tote 10 to be supported on the stacking surfaces 24 (FIG. 1) of the lower tote 10 on both side walls 14.

[0066] FIG. 3 shows the upper tote 10 nested in the tote 10 of FIG. 1. The upper tote 10 is rotated to the same orientation as the lower tote 10 such that the outer columns 23 of the upper tote 10 are received in the inner channels 20 of the lower tote 10.

[0067] FIG. 4 shows the tote 10 of FIG. 1 with a lid 30 on the upper edges of the side walls 14 and end walls 16, optionally with a snap-fit engagement. The lid 30 includes an upper surface having a recess 32 formed therein having a perimeter that substantially matches the footprint of the base 12 of the tote 10. An adjacent pair of supporting surfaces 34 are formed next to one another at each corner of the recess 32 along the side edges. The supporting surfaces 34 are similar to the stacking surfaces 24 on the inner columns 22 of the tote 10 and are configured to receive the outer columns 23 of the identical tote 10 the same way in either orientation. In one orientation, the outer columns 23 will be received in one supporting surface 34 of each adjacent pair of supporting surfaces 34. In the 180-degree orientation, the outer columns 23 will be received in the other supporting surface 34 of each adjacent pair of supporting surfaces 34. A large cove 36 is formed along each side edge of the recess 32. Each large cove 36 is configured to receive the large central column 26 of a tote 10 stacked thereon.

[0068] In this example, in one orientation, the outer columns 23 of one side wall 14 will be received in the inner ones of supporting surfaces 34 and the outer columns 23 of the other side wall 14 will be received in the outer ones of the supporting surfaces 34. In the 180-degree orientation, the outer columns 23 of one side wall 14 will be received in the outer ones of supporting surfaces 34 and the outer columns 23 of the other side wall 14 will be received in the inner ones of the supporting surfaces 34.

[0069] FIG. 5 shows the tote 10 and lid 30 of FIG. 4 with the identical tote 10 stacked thereon. The base 12 of the upper tote 10 is received in the recess 32 of the lid 30. The outer columns 23 of the upper tote 10 are received in one supporting surface 34 of each pair of supporting surfaces 34 of the lid 30. As shown, the upper tote 10 will stack on the lid 30 in either 180-degree orientation.

[0070] FIG. 6 shows a tray 50 that is currently used in an existing automated storage and retrieval system (ASRS). The tray 50 includes a plurality of parallel ribs as a base with a plurality of retention fingers protruding upward from a periphery of the base.

[0071] The base 12 of the tote 10 is substantially smaller than the upper edge of the tote 10 (because it is nestable) and the base 12 is substantially smaller than the base of the tray 50. Because the distances between the retention fingers on opposing edges are larger than the base 12 of the tote 10, the base 12 of the tote 10 could be mispositioned toward one edge of the tray 50, thereby bringing the upper edge of the tote 10 outside the footprint of the tray 50, which is undesirable in the ASRS.

[0072] FIG. 7 shows the lid 30 received in the tray 50. The lid 30 is configured to be received on the ribs of the base of the tray 50 and to be received between the retention fingers of the tray 50. The lid 30 is slightly bigger than the upper edges of the tote 10, i.e., slightly bigger than the footprint of the tote 10. The lid 30 is dimensioned to fit between the retention fingers of the tray 50, with a few millimeters clearance on each side.

[0073] FIG. 8 shows the tote 10 received in the recess 32 of the lid 30 on the tray 50. The lid 30 locates the tote 10 more centrally on the tray 50 such that the upper edges of the tote 10 cannot protrude outward of the footprint of the tray 50. As shown in FIG. 9, the lid 30 locates the tote 10 centrally on the tray 50 between side edges of the tray 50. As shown in FIG. 10, the lid 30 locates the tote 10 centrally on the tray 50 between end edges of the tray 50.

[0074] FIG. 11 is a top view of a tote 110 according to a second embodiment. The tote 110 could be used with the lid 30 and tray 50 in the exact same way as the previous embodiment. The tote 110 is identical to the tote 10 of FIGS. 1-10, with only a different base 112. A grid of ribs 138 protrudes upward from an upper surface of the base 112. The ribs 138 reinforce the base 112. The bases 12, 112 do not have ribs on the bottom surface because a smooth bottom surface is preferred for use in the ASRS.

[0075] Additionally, short product retention cross-ribs 140 are formed perpendicularly to the ribs 138. The ribs 138 define a plurality of product retention recesses on the base 112 between the free ends of the ribs 138. For example, a jar 70 is shown on the base 112 retained by the short product retention cross-ribs 140. The short product retention cross-ribs 140 extend perpendicularly to the jar 70. A similar jar 70 can be securely placed in each of the product retention recesses on the base 112. Other than the base 112, the rest of the tote 110 may be identical to the tote 10 of FIG. 1, and the tote 110 may be used with the lid 30 in the same way. Additionally, the tote 10 of FIG. 1 would stack and nest with the tote 110 of FIG. 11 in the same way that they each stack and nest with identical totes 10, 110.

[0076] FIG. 12 is a section view taken along line A-A of FIG. 11. In this embodiment, the short product retention cross-ribs 140 are the same height as the ribs 138; however, alternatively, the short product retention cross-ribs 140 could be a little taller than the ribs 138. The short product retention cross-ribs 140 abut the jar 70 to retain the jar 70 in position on the base 112. A plurality of jars, cans, or other small containers could be retained on the base 112, each retained in one of the plurality of product retention recesses by a plurality of short product retention cross-ribs 140. Again, the bottom surface of the base 112 is preferably substantially smooth.

[0077] FIG. 13A is an upper perspective view of a tote 210 according to a third embodiment. FIG. 13B is a perspective view of the interior of the tote 210, partially broken away. In this embodiment, a product retention rib 240 extends circumferentially about a portion of the product retention recess and the jar 70 in each product retention recess. The side walls and / or end walls may also define a portion of each product retention recess. The product retention ribs 240 are molded integrally with the base 212. Only four product retention ribs 240 are shown, but more or fewer can be provided. Additional product retention ribs 240 could be provided away from the walls, such that the product retention rib 240 completely encircles the product retention recess. The product retention rib 240 may be formed as a substantial portion of the height of the jars 70, such as approximately ⅓ the height of the jars 70. However, as shown in the section view of FIG. 13C, the product retention ribs 240 are still short enough to permit an identical tote 210 to be nested in the tote 210 without the base 212 of the upper tote 210 contacting the product retention ribs 240. Other than the base 212, the rest of the tote 210 is identical to the tote 10 of FIG. 1, and the tote 210 may be used with the lid 30 in the same way.

[0078] FIG. 14A is an upper perspective view of a tote 310 according to a fourth embodiment. FIG. 14B is a perspective view of the interior of the tote 310, partially broken away. In this embodiment, a product retention rib 340 extends partially circumferentially in segments about a portion of the product retention recess and the jar 70 in each product retention recess. The side walls and / or end walls define a portion of each product retention recess. The product retention ribs 340 are molded integrally with the base 312. The product retention rib 340 may be formed as a substantial portion of the height of the jars 70, such as approximately ⅓ the height of the jars 70. However, as shown in the section view of FIG. 14C, the product retention ribs 340 are still short enough to permit an identical tote 310 to be nested in the tote 310 without the base 312 of the upper tote 310 contacting the product retention ribs 340. Other than the base 312, the rest of the tote 310 may be identical to the tote 10 of FIG. 1, and the tote 310 may be used with the lid 30 in the same way. Four product retention ribs 340 are shown, but more or fewer can be provided. Additional product retention ribs 340 could be provided away from the walls, such that the product retention rib 340 provides retention in all directions (although segmented).

[0079] FIG. 15A is an upper perspective view of a tote 410 according to a fifth embodiment. In this embodiment, flexible product retention straps 440 are removably secured to one or more walls of the tote 410 to define the product retention recesses, and the jars 70 are retained in each product retention recess. The side walls and / or end walls define a portion of each product retention recess. FIG. 15B is a perspective view of one of the flexible product retention straps 440. The flexible product retention straps 440 each include a clip 442 at each end that can slidably engage a slot 444 defined by ribs molded into one of the walls of the tote 410, as shown in FIG. 15C.

[0080] FIG. 15D is a section view through two nested totes 410. The flexible product retention straps 440 are short enough and low enough to permit an identical tote 410 to be nested in the tote 410 without the base 412 of the upper tote 410 contacting the flexible product retention straps 440.

[0081] Other than the base 412 and the slots 444, the rest of the tote 410 may be identical to the tote 10 of FIG. 1, and the tote 410 may be used with the lid 30 in the same way. Four flexible product retention straps 440 are shown, but more or fewer can be provided. As shown in FIG. 15E, the flexible product retention straps 440 can be removed from the slots 444 and then laid flat on the upper surface of the base 412 when not in use.

[0082] FIG. 16A is an upper perspective view of a tote 510 according to a sixth embodiment. In this embodiment, flexible product retention straps 540 are removably secured to one or more walls of the tote 510 to define the product retention recesses, and the jars 70 are retained in each product retention recess. The side walls and / or end walls define a portion of each product retention recess.

[0083] FIG. 16B is a perspective view of the interior of the tote 510, partially broken away. The flexible product retention straps 540 each include a fastener at each end, such as complementary hook and loop fasteners, that can slide through slots 546 molded into one or more of the walls of the tote 510 and then connect to one another on the exterior of the tote 510, as shown in FIG. 16C.

[0084] FIG. 16D is a section view through a pair of nested totes 510. The flexible product retention straps 540 are short enough and low enough to permit an identical tote 510 to be nested in the tote 510 without the base 512 of the upper tote 510 contacting the flexible product retention straps 540. Other than the slots 546, the rest of the tote 510 may be identical to the tote 10 of FIG. 1, and the tote 510 may be used with the lid 30 in the same way. Four flexible product retention straps 540 are shown, but more or fewer can be provided. Again, the flexible product retention straps 540 can be removed from the slots 546 and then laid flat on the upper surface of the base 512 when not in use.

[0085] FIG. 17A is a perspective view of a tote 610 according to a seventh embodiment. In this embodiment, interlocking dividers 640 are inserted into the tote 610 onto the base 612 between walls of the tote 610. The dividers 640 define the product retention recesses, and the jars 70 are retained in each product retention recess. FIG. 17B shows the dividers 640 being inserted into the tote 610.

[0086] FIG. 17C is an exploded perspective view of the dividers 640. The dividers 640 interlock with one another, as shown, such as by connecting slots on perpendicular dividers 640. The dividers 640 may be cardboard, plastic, paperboard, or other suitable material. The side walls and / or end walls define a portion of some of the product retention recesses.

[0087] FIG. 17D is a section view through a pair of nested totes 610. The dividers 640 are short enough and low enough to permit an identical tote 610 to be nested in the tote 610 without the base 612 of the upper tote 610 contacting the dividers 640. In this example, the rest of the tote 610 may be identical to the tote 10 of FIG. 1, and the tote 610 may be used with the lid 30 in the same way. Only four dividers 640 are shown (two in one direction and two perpendicular), but more or fewer can be provided. The dividers 640 can be disengaged from one another and then laid flat on the upper surface of the base 612 when not in use; however, this is not necessary for nesting the empty totes 610.

[0088] FIG. 18 is a top view of a tote 710 according to an eighth embodiment. In this embodiment, short product retention ribs 740 are molded integrally with the base 712 between walls of the tote 710 to define the product retention recesses, and the jars 70 (not shown) are retained in each product retention recess. The bottom surface of the base 712 is again smooth or substantially smooth, or at least rib-free. The side walls and / or end walls define a portion of some of the product retention recesses. The short product retention ribs 740 are short enough and low enough to permit an identical tote 710 to be nested in the tote 710 without the base 712 of the upper tote 710 contacting the short product retention ribs 740. In this example, the rest of the tote 710 is identical to the tote 10 of FIG. 1, and the tote 710 may be used with the lid 30 in the same way. In this example, the short product retention ribs 740 do not completely encircle the product retention recesses, but leave large gaps. Most of the short product retention ribs 740 partially define more than one product retention recess.

[0089] FIG. 19 is a top view of a tote 810 according to a ninth embodiment. In this embodiment, a grid of reinforcing ribs 838 are molded integrally with the base 812 and extend continuously from one side wall to the other and from one end wall to the other. These reinforcing ribs 838 reinforce the base 812. The bottom surface of the base 812 again would be smooth or substantially smooth or at least rib-free. Short product retention ribs 840 are molded integrally with the base 812 between walls of the tote 810 to define the product retention recesses and the jars 70 (not shown) are retained in each product retention recess. The reinforcing ribs 838 may be curved to round off corners formed by the reinforcing ribs 838. Portions of the reinforcing ribs 838, the side walls and / or end walls define a portion of some of the product retention recesses. The reinforcing ribs 838 and the short product retention ribs 840 are short enough and low enough to permit an identical tote 810 to be nested in the tote 810 without the base 812 of the upper tote 810 contacting the short product retention ribs 840. In this example, the rest of the tote 810 (other than the base 812) may be identical to the tote 10 of FIG. 1 and the tote 810 may be used with the lid 30 in the same way.

[0090] FIG. 20 is a top view of a tote 910 according to a tenth embodiment. In this embodiment, a plurality of ribs 940 are molded integrally with the base 912 and extend continuously from one side wall to the other and from one end wall to the other. These ribs 940 reinforce the base 912 and define product retention recesses. In this arrangement, the ribs 940 are formed in a grid but are formed in a diamond at each intersection. This provides a more snug fit with the jars 70 (not shown). The bottom surface of the base 912 again would be smooth or substantially smooth or at least rib-free. The jars 70 (not shown) would be retained in each product retention recess. The walls of the tote 910 may define a portion of some of the product retention recesses. The ribs 940 are short enough and low enough to permit an identical tote 910 to be nested in the tote 910 without the base 912 of the upper tote 910 contacting the ribs 940. In this example, the rest of the tote 910 (other than the base 912) is identical to the tote 10 of FIG. 1 and the tote 910 may be used with the lid 30 in the same way.

[0091] FIG. 21 is a top view of a tote 1010 according to an eleventh embodiment. FIG. 22 is an upper perspective view of the tote 1010 of FIG. 21. The tote 1010 could be used with the lid 30 and tray 50 in the exact same way as the previous embodiment. The tote 1010 is identical to the tote 10 of FIGS. 1-10 with one exception. A grid of ribs 1038 protrudes upward from an upper surface of the base 1012, connecting the end walls to one another and connecting the side walls to one another. The ribs 1038 reinforce the base 1012 (the bases 12, 1012 do not have ribs on the bottom surface because of the ASRS).

[0092] Additionally, short product retention cross-ribs 1040 are formed perpendicularly to the ribs 1038. The ribs 1038 define a plurality of product retention recesses on the base 1012. For example, a jar 70 is shown on the base 1012 retained by the short product retention cross-ribs 1040. The short product retention cross-ribs 1040 extend perpendicularly to the jar 70. The height of the short product retention cross-ribs 1040 is tapered down to the base 1012 at each free end. A similar jar 70 can be securely placed in each of the product retention recesses on the base 1012. Other than the base 1012, the rest of the tote 1010 may be identical to the tote 10 of FIG. 1 and the tote 1010 may be used with the lid 30 in the same way.

[0093] For any of the totes with product retention recesses, the totes may carry a plurality of jars 70 in the product retention recesses, or one or more jars 70 in the product retention recesses with additional items on top, such as bags of chips. The totes could still be used without the jars 70 and be used just to carry other items, such as bags of chips, on top of the ribs or other product retention features. Alternatively, as shown above, some of the product retention features can be removed and laid flat on the base of the tote so that other items (such as bags of chips) can be placed on top. The totes 10, 110, 210, 310, 410, 510, 610, 710, 810, 910, 1010 of FIGS. 1, 11, 13A, 14A, 15A, 16A, 17A, 18, 19, 20, 21 can all stack and nest with one another in the same way that they do with identical totes. Product retention features may also be combined in a single embodiment, e.g., ribs and straps.

[0094] One embodiment of a pallet assembly 1100 that can be used with all of the preceding totes is shown in FIG. 23. The example pallet assembly 1100 shown includes a pallet 1110, which may be a half pallet, and a top deck 1111 secured to the pallet 1110. The pallet 1110 is integrally molded as a single piece of plastic, such as by injection molding. Pallet 1110 includes a deck 1112. Feet 1114 or columns project downward from the deck 1112 to support the deck 1112 above the floor so that tines of a pallet jack, pallet lift, forklift, or other pallet handling equipment can be inserted between the feet 1114. Openings 1116 are formed through the top deck 1111 and in the deck 1112 above each of the feet 1114. The openings 1116 can receive the feet 1114 of an identical pallet assembly 1100 stacked thereon and partially received in the deck 1112 for stability. Handle openings 1120 are formed through the top deck 1111 and deck 1112. A plurality (in this example, three) recesses 1132 are formed in the upper surface of the top deck 1111. As will be explained, each of the recesses 1132 is configured to receive any of the totes disclosed above. Alternatively, the plurality of recesses 1132 may be integrally molded into the upper surface of the deck 1112 of the pallet 1110.

[0095] FIG. 24 is an exploded perspective view of the pallet assembly 1100. The deck 1112 has an upper support surface 1118 upon which goods can be supported and on which the top deck 1111 is secured. The upper surface 1118 is defined by an upper planar portion. The deck 1112 is then welded to the upper support surface 1118 of the pallet 1110. Alternatively, the deck 1112 is secured to the upper support surface 1118 by adhesive, fasteners, snap-fit connections, or some combination thereof.

[0096] FIG. 25 is a top view of the top deck 1111. Each recess 1132 is substantially similar to the recess 32 formed in the lid 30 of FIG. 4. Deck recess 1132 interlock geometry may vary independently from lid 30 interlock geometry, provided dimensional clearances are maintained within specified tolerances to ensure reliable vertical load transfer and stable stacked tote engagement.

[0097] Each recess 1132 has a perimeter that substantially matches the footprint of the base 12 of the tote 10. An adjacent pair of supporting surfaces 1134 are formed next to one another at each corner of the recess 1132 along the side edges (some are interrupted by the openings 1116). The supporting surfaces 1134 are similar to the stacking surfaces on the inner columns of the totes and are configured to receive the outer columns of the identical tote the same way in either orientation. A large cove 1136 is formed along each side edge of the recess 1132. Each large cove 1136 is configured to receive the large central column 26 (FIG. 1) of a tote 10 stacked thereon.

[0098] The recesses 1132 enable secure stacking on the upper support surface 1118 of the pallet 1110. A variety of tote interlock options are possible, but top deck 1111 should have aligned handle hole openings and openings for the legs to stack with the pallet.

[0099] The top deck 1111 would receive any of the totes disclosed herein because they all have the same base structure and columns. The recesses 1132 would keep the totes in place on the pallet assembly 1100.

[0100] FIG. 26 is a perspective view of the pallet assembly 1100 with three of the totes 10 thereon; however, any combination of the totes 10, 110, 210, 310, 410, 510, 610, 710, 810, 910, 1010 disclosed herein could be used. Each tote 10 is received in one of the three recesses 1132.

[0101] FIG. 27 shows the pallet assembly 1100 and totes 10 of FIG. 26 with additional layers of totes 10 stacked thereon. Additional layers of totes (of any of the disclosed designs) could be stacked on the first layer of totes 10, either using the stacking columns as shown or using the lids 30. In this manner, the totes 10 can be securely stacked on the pallet assembly 1100 and moved by a pallet jack, pallet lift, fork lift, or other pallet handling equipment. The recesses 1132 enable secure stacking on the upper support surface 1118 of the pallet assembly 1100. When stacking multiple layers of totes 10 on the pallet assembly 1100, the lid 30 is not required for stacking totes 10, unless additional internal storage height inside the lid 30 or security of contents in the tote 10 is preferred.

[0102] FIG. 28 is a perspective view of one tote 10 with a lid 30 interlocked with one of the recesses 1132 of the pallet assembly 1100. The large central column 26 is received in one of the large coves 1136 of the recess 1132.

[0103] FIG. 29 is a perspective view of three totes 10 with lids 30, each interlocked with one of the recesses 1132 of a pallet assembly 1100. FIG. 30 is an end view of the totes 10 and pallet assembly 1100 of FIG. 29. FIG. 31 is a side view of the totes 10 and pallet assembly 1100 of FIG. 29. FIG. 32 is a perspective view of a plurality of layers of totes 10 with lids 30 stacked on the pallet assembly 1100.

[0104] FIG. 33 is a perspective view of the pallet assembly 1100 with an identical pallet assembly 1100 stacked thereon, with the feet 1114 of the upper pallet assembly 1100 received in the openings 1116 of the lower pallet assembly 1100. FIG. 34 is an end view of the pallet assemblies 1100 of FIG. 33.

[0105] In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.

Claims

1. A nestable tote comprising:a base including a bottom surface and an upper surface; opposing side walls extending upward from side edges of the base;opposing end walls extending upward from end edges of the base; anda plurality of product retention features above the upper surface of the base to define a plurality of product retention recesses configured to retain items therein, wherein the product retention features are configured to permit an identical tote to nest therein without a base of the identical tote contacting the product retention features.

2. The nestable tote of claim 1 wherein the product retention features include a grid of ribs protruding upward from the upper surface of the base.

3. The nestable tote of claim 2 further including short product retention cross-ribs formed perpendicularly to the ribs, the short product retention cross-ribs configured to abut the items in the product retention recesses.

4. The nestable tote of claim 1 wherein the product retention features include product retention ribs protruding upward from the upper surface of the base and extending at least partially circumferentially about each of the product retention recesses.

5. The nestable tote of claim 4 wherein the product retention ribs are segmented.

6. The nestable tote of claim 1 wherein the product retention features include flexible straps removably secured to at least one of the side walls or end walls, the flexible straps defining at least portions of the product retention recesses.

7. The nestable tote of claim 6 wherein the flexible straps are removable and configured to lay flat on the upper surface of the base when not in use.

8. The nestable tote of claim 1 wherein the product retention features include interlocking dividers insertable onto the upper surface of the base, the dividers defining the product retention recesses.

9. The nestable tote of claim 8 wherein the dividers are disengageable and configured to lay flat on the upper surface of the base when not in use.

10. The nestable tote of claim 1 wherein the product retention features include short product retention ribs protruding upward from the upper surface of the base and that do not completely encircle the product retention recesses and partially define multiple product retention recesses.

11. The nestable tote of claim 1 wherein the product retention features include a grid of reinforcing ribs with curved portions to round off corners, and short product retention ribs cooperating therewith to define the product retention recesses.

12. The nestable tote of claim 1 wherein the product retention features include ribs formed in a grid with diamond-shaped intersections configured to provide a snug fit for the items.

13. The nestable tote of claim 1 wherein the bottom surface of the base is smooth.

14. A system comprising:the nestable tote of claim 1; anda lid securable to upper edges of the side walls and end walls, the lid including an upper recess configured to receive a base of an identical tote for stacking.

15. The system of claim 14 further including a tray having a base with ribs and peripheral retention fingers, wherein the lid is configured to fit between the retention fingers and center the nestable tote on the tray such that upper edges of the nestable tote do not protrude beyond a footprint of the tray.

16. A system comprising:the nestable tote of claim 1; anda pallet having an uppermost surface having at least one recess configured to receive the base of the nestable tote for secure positioning.

17. The system of claim 16 wherein the at least one recess includes a plurality of recesses, each configured to receive one of a plurality of nestable totes.

18. The system of claim 17 further including a lid securable to the nestable tote, the lid including an upper recess configured to receive a base of an identical tote for stacking.

19. A pallet comprising:a deck;a plurality of feet projecting downward from the deck to support the deck above a floor; andan upper surface of the deck having at least one recess formed therein, the at least one recess having a perimeter configured to receive a base of a tote, the at least one recess including a pair of adjacent supporting surfaces at each corner thereof configured to receive outer columns of the tote in either of two 180-degree rotated orientations, the at least one recess further including coves along side edges thereof configured to receive central columns of the tote.

20. The pallet of claim 19 further including a top deck secured to the pallet, wherein the top deck includes the upper surface and the at least one recess, wherein the at least one recess includes a plurality of recesses, each configured to receive one of a plurality of totes, wherein the top deck includes openings aligned with the feet of the pallet, the openings configured to receive feet of an identical pallet assembly stacked thereon.

21. A method of transporting totes comprising:placing at least one tote into at least one recess formed in an upper surface of a pallet, the pallet having a deck and a plurality of feet projecting downward from the deck, wherein the at least one recess has a perimeter receiving a base of the at least one tote and includes a pair of adjacent supporting surfaces at each corner thereof receiving outer columns of the at least one tote in one of two 180-degree rotated orientations, the at least one recess further including coves along side edges thereof receiving central columns of the at least one tote; andmoving the pallet with the at least one tote secured therein using pallet handling equipment.

22. The method of claim 21 further including stacking a plurality of layers of additional totes on the at least one tote in the at least one recess.

23. The method of claim 21 further including securing a lid to the at least one tote prior to placing the at least one tote into the at least one recess, wherein the lid is received in the at least one recess.

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