Packaging for tote shelf assembly and method

Abstract

A packaging system for a shelf assembly is provided. The packaging system may include a plurality of shelf panels arranged in a stacked configuration. The plurality of shelf panels may include a bottom shelf panel, a top shelf panel, and at least one intermediate shelf panel. The plurality of shelf panels may form a hollow interior. The packaging system may include a plurality of poles positioned within the hollow interior and a plurality of additional components positioned within the hollow interior.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 772,897, filed on Mar. 17, 2025. The entire disclosure of the above application is incorporated herein by reference.FIELD

[0002] The present technology relates to modular storage systems, and more particularly, to a configurable shelf assembly and related packaging for efficient shipping, storage, and user assembly.INTRODUCTION

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Shelf systems often utilize a fixed configuration, limiting the adaptability of shelf systems with respect to different spaces and user needs. The lack of flexibility may present challenges in modern living environments where space optimization is necessary and / or preferred. Additionally, an inability to easily reconfigure or expand the shelf systems may lead to premature replacement of the shelf systems, contributing to unnecessary waste. Fixed configurations may also lead to inefficient packing and shipping of the shelf systems as the packaging containers may need to be adjusted or modified to conform to the shelf systems, thereby increasing packaging costs.

[0005] Modular storage systems, particularly configurable shelf assemblies, can be versatile and adaptable to various living and storage spaces. However, shipping, storage, and assembly of configurable shelf assemblies may present unique challenges compared to fixed shelf assemblies. For example, a configurable shelf assembly may include multiple components that are shipped separately, leading to increased packaging materials and waste, as well as increased shipping, storage, and inventory management costs. Separate shipping may also increase the risk of components being lost or damaged during transit and the risk of the end user receiving the wrong components.

[0006] For configurable shelf assemblies shipped as a single unit, suboptimal arrangement and packaging of various components may result in damaged pieces and parts. For example, suboptimal packaging may result in a heavier component damaging a smaller component during packing or transport. What is more, common materials used for configurable shelf assemblies are often excessively heavy when packaged together and, as a result, difficult for the end user to lift and move. Heavy materials and components may also result in increased shipping costs, thereby decreasing profit for the manufacturer and / or increasing the cost for the end user.

[0007] Configurable shelf assemblies often also include confusing, hard to follow assembly instructions such as text-heavy manuals or complex diagrams. Complex instructions may leave the end user confused and frustrated during assembly and may result in the product being assembled incorrectly. Assembly errors may compromise operation of the product, thereby affecting the quality and safety of the configurable shelf assembly. Additional tools required for assembly and installation of configurable shelf assemblies may also be required, further complicating the assembly process for the end user.

[0008] Accordingly, there is a continuing need for a configurable shelf assembly system that addresses challenges with respect to shipping, storage, and assembly of the configurable shelf assembly. Desirably, such a system may be configured for efficient packaging for reduced shipping, storage, and inventory management costs, provide clear and intuitive assembly instructions, allow for easy reconfiguration and expansion, utilize lightweight yet durable materials, and maintain stability and structural integrity throughout the shipping and assembly process.SUMMARY

[0009] In concordance with the instant disclosure, a configurable shelf assembly system that is configured for efficient packaging for reduced shipping, storage, and inventory management costs, provides clear and intuitive assembly instructions, allows for easy reconfiguration and expansion, utilizes lightweight yet durable materials, and maintains stability and structural integrity throughout the shipping and assembly process, has surprisingly been discovered. The present technology includes articles of manufacture, systems, and processes that relate to modular storage systems, and more particularly, to configurable shelf assemblies and related packaging configured for efficient and organized shipping, storage, and user assembly.

[0010] In certain embodiments, a packaging system for a shelf assembly may include a plurality of shelf panels arranged in a stacked configuration. The plurality of shelf panels may include a bottom shelf panel, a top shelf panel, and at least one intermediate shelf panel. The plurality of shelf panels may form a hollow interior. The packaging system may include a plurality of poles positioned within the hollow interior and a plurality of additional components positioned within the hollow interior.

[0011] In certain embodiments, a method of assembling a packaging system for a shelf assembly may include a first step of providing a plurality of shelf panels arranged in a stacked configuration. The plurality of shelf panels may include a bottom shelf panel, a top shelf panel, and at least one intermediate shelf panel. The plurality of shelf panels may form a hollow interior. The packaging system may include a plurality of poles and a plurality of additional components. Steps including positioning the bottom shelf panel as a base of the packaging system, placing the at least one intermediate shelf panel on top of the bottom shelf panel, and positioning the top shelf panel on top of the at least one intermediate shelf panel may be included. Each of the bottom shelf panel, the at least one intermediate shelf panel, and the top shelf panel may be positioned in a stacked configuration and may form the hollow interior. The method may further include positioning the plurality of poles and the plurality of additional components within the hollow interior.

[0012] In certain embodiments, a method of assembling a packaging system for a shelf assembly may include a first step of providing a plurality of shelf panels arranged in a stacked configuration. The plurality of shelf panels may include a bottom shelf panel, a top shelf panel, and at least one intermediate shelf panel. The plurality of shelf panels may form a hollow interior. The packaging system may include a plurality of poles, a plurality of additional components, and a plurality of storage totes. Additional steps may include positioning the bottom shelf panel as a base of the packaging system, placing the at least one intermediate shelf panel on top of the bottom shelf panel, and positioning the top shelf panel on top of the at least one intermediate shelf panel. Each of the bottom shelf panel, the at least one intermediate shelf panel, and the top shelf panel may be positioned in a stacked configuration and may form the hollow interior. A step of positioning the plurality of storage totes in the hollow interior may be included in the method. A top storage tote of the plurality of storage totes may have a hollow interior space. A step including positioning the plurality of poles and the plurality of additional components within the hollow interior space of the top storage tote may also be included.

[0013] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.DRAWINGS

[0014] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure.

[0015] FIG. 1 is a top perspective view of a packaging system for a shelf assembly, according to an embodiment of the present disclosure;

[0016] FIG. 2 is a top plan view thereof;

[0017] FIG. 3 is a top perspective view of additional components and a component carton of a packaging system for a shelf assembly, according to an embodiment of the present disclosure;

[0018] FIG. 4 is a top perspective view of a packaging system for a shelf assembly, according to an embodiment of the present disclosure;

[0019] FIG. 5 is a top perspective view of a packaging system for a shelf assembly including totes and lids, according to an embodiment of the present disclosure;

[0020] FIG. 6 is top perspective view thereof shown without the lids;

[0021] FIG. 7 is a partially exploded top perspective view thereof;

[0022] FIG. 8 is a schematic block diagram illustrating a packaging system for a shelf assembly, according to an embodiment of the present disclosure;

[0023] FIG. 9 is a schematic block diagram illustrating a packaging system for a shelf assembly, according to an embodiment of the present disclosure;

[0024] FIG. 10 is a schematic block diagram illustrating a method of assembling a packaging system for a shelf assembly, according to an embodiment of the present disclosure; and

[0025] FIG. 11 is a schematic block diagram of a method of assembling a packaging system for a shelf assembly, according to an embodiment of the present disclosure.DETAILED DESCRIPTION

[0026] The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments, including where certain steps can be simultaneously performed, unless expressly stated otherwise. “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “substantially” in describing the broadest scope of the technology. “About” when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” and / or “substantially” is not otherwise understood in the art with this ordinary meaning, then “about” and / or “substantially” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters.

[0027] Although the open-ended term “comprising,” as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments may alternatively be described using more limiting terms such as “consisting of” or “consisting essentially of.” Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or process steps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that may be recited in the art, even though element D is not explicitly described as being excluded herein.

[0028] As referred to herein, disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of “from A to B” or “from about A to about B” is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter may define endpoints for a range of values that may be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of 1–10, or 2–9, or 3–8, it is also envisioned that Parameter X may have other ranges of values including 1–9, 1–8, 1–3, 1–2, 2–10, 2–8, 2–3, 3–10, 3–9, and so on.

[0029] When an element or layer is referred to as being “on,”“engaged to,”“connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,”“directly engaged to,”“directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,”“adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0030] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,”“second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0031] Spatially relative terms, such as “inner,”“outer,”“beneath,”“below,”“lower,”“above,”“upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0032] The present technology improves shipping, storage, and assembly of modular storage systems. Specifically, the present technology militates against increased packaging materials and shipping costs due to separately shipped components, inefficient packaging, and heavy components. The present technology further militates against risk of lost or damaged parts during transit, confusing assembly instructions, and complex and time-consuming assembly processes.

[0033] With reference to FIGS. 1-9, a packaging system 100 for a shelf assembly 101 is shown. The packaging system 100 may include one or more shelf panels 102 arranged in a stacked configuration. The shelf panels 102 arranged in the stacked configuration may form a hollow interior 104. It should be appreciated that an entirety of a plurality of the shelf panels 102 in a stacked configuration may form the hollow interior 104. As an example, as shown in FIG. 1, a plurality of five shelf panels 102 may collectively form the hollow interior 104. Advantageously, the hollow interior 104 formed by the shelf panels 102 may be used to store additional components 106 of the packaging system 100, such as one or more poles 108, top caps 110, foot assemblies 112, wall securing mechanisms 114, interlocking components 116, and shelf dividers 118, to optimize efficient packaging of the shelf assembly 101, reduce shipping, storage, and inventory costs, and militate against the risk of lost or damaged components during transportation. Desirably, the packaging system 100 may provide a user with every component necessary to assemble the shelf assembly 101 in a desired configuration without the need for specialized tools and equipment.

[0034] The shelf panels 102 may include a bottom shelf panel 120, at least one intermediate shelf panel 122, and a top shelf panel 124. The bottom shelf panel 120 may be configured as a base and may be positioned at the bottom of the packaging system 100. The shelf panels 102 may be formed from lightweight materials such as polypropylene plastic. The shelf panels 102 may alternatively be formed of other materials such as polyethylene, foam, or metal. One of ordinary skill in the art may select a suitable material or combination of materials to form the shelf panels 102 within the scope of the present disclosure.

[0035] Each shelf panel 102 may include a first panel member 126, a second panel member 128, a third panel member 130, and a cross member 132 configured to form a portion of the hollow interior 104. Each shelf panel 102 may be configured to facilitate the insertion and sliding of a storage tote 134 for suspension from the shelf panel 102 in the assembled shelf assembly 101. In certain embodiments, one or more of the shelf panels 102 may include the first panel member 126, the second panel member 128, and the third panel member 130, and may not include the cross member 132. The cross member 132 may be configured to enhance the structural integrity of the shelf panel 102 and may be included or not included in selected ones or all of the shelf panels 102 as desired, for example, based on user requirements, desired load carrying capacity, and materials selected to form the shelf panels 102.

[0036] Each of the first panel member 126, the second panel member 128, the third panel member 130, and the cross member 132 may be an elongated member and may have any suitable size, shape, and configuration, such as a rectangular cross sectional shape, as an example. Each shelf panel 102 may include support ribs 136 disposed on a bottom surface and may be configured to enhance the structural integrity of each shelf panel 102 and the packaging system 100 when the shelf panels 102 are arranged in the stacked configuration. It should be appreciated that the support ribs 136 of one shelf panel 102 may be configured to abut a shelf panel 102 disposed directly underneath.

[0037] Each shelf panel 102 may include one or more apertures 138 disposed therethrough, as shown in FIGS. 1 and 4. In certain embodiments, apertures 138 may be disposed adjacent each corner 140 of the shelf panel 102 and / or adjacent a section of the shelf panel 102 where any two of the first panel member 126, the second panel member 128, the third panel member 130, and the cross member 132 come together. One of ordinary skill in the art may select any suitable shape, size, and configuration for the aperture 138 within the scope of the present disclosure. It should be appreciated that any suitable structural elements configured to facilitate assembly and enhance stability may be included, as determined by a skilled artisan.

[0038] The packaging system 100 may include additional components 106 such as one or more poles 108. Each pole 108 may be elongated and may be configured for insertion into one or more apertures 138 of the shelf panels 102. The poles 108 may be uniform in length and / or may have variable lengths. In certain embodiments, a first set of poles 142 may have a first uniform length 146, and a second set of poles 144 may have a second uniform length 148 that is different from the first uniform length 146 of the first set of poles 142, thereby providing variable distances between successive shelf panels 102 in the assembled shelf assembly 101.

[0039] The poles 108 may be configured to couple and stack each of the shelf panels 102 to one another. It should be appreciated that the poles 108 may be configured to provide any desired spacing between two successive shelf panels 102, as determined by a skilled artisan. Advantageously, the poles 108 may be configured to fit in the hollow interior 104 formed by the shelf panels 102 during storage and transport of the packaging system 100. The length of each pole 108 may be selected to provide a desired distance between successive shelf panels 102 and to fit within the hollow interior 104. The poles 108 may include fixed, rigid poles 108, telescoping poles 108, and / or any other suitable poles 108, as desired. In certain embodiments, at least one end 150 of each pole 108 may include an insertion portion 152 configured to be received by the aperture 138. It should be appreciated that the poles 108 may be individually included in the hollow interior 104, secured to one another, and / or secured to the shelf panels 102 and / or additional components 106 of the packaging system 100. A protective wrap 194 and / or other material, such as bubble wrap or cardboard, may be used to militate against damage to the poles 108 during transport of the packaging system 100.

[0040] The packaging system 100 may also include a component carton 154 configured to include one or more of the additional components 106 of the packaging system 100. As shown in FIGS. 1 and 3, the component carton 154 may include additional components 106 such as one or more top caps 110, foot assemblies 112, wall securing mechanisms 114, and interlocking components 116, as examples. Each of the additional components 106 may be stored in the component carton 154 during transport. The component carton 154 may be fabricated using any material or combination of materials such as cardboard or plastic, as examples, and may include a padding material such as bubble wrap or packing paper, as examples. Any suitable shape, size, and configuration may be used to form the component carton 154. In certain embodiments, more than one component carton 154 may be included in the packaging system 100. Advantageously, the component carton 154 may be a size, shape, and configuration capable of housing the additional components 106 in such a way as to militate against movement of and damage to the additional components 106. In certain embodiments, the poles 108 and / or the shelf dividers 118 may be included in the component carton 154, as determined by one of skill in the art.

[0041] The top caps 110 may be configured to be received in the apertures 138 formed in the top shelf panel 124. Each top cap 110 may include a top portion 156 and a bottom portion 158. The bottom portion 158 may be configured to be received in the aperture 138 of the top shelf panel 124 and the top portion 156 may abut a top surface 160 of the top shelf panel 124, thereby covering the aperture 138. The bottom portion 158 may be configured to be removably secured in the aperture 138 using a friction fit, a snap fit, a threaded fit, or any other suitable connecting mechanism. One of ordinary skill in the art may select any suitable top cap 110 within the scope of the present disclosure.

[0042] The foot assemblies 112 may include one or more of a flat foot 162, a foot adjuster 164 configured to cooperate with and couple to the flat foot 162, and a wheeled foot 166. Each of the flat foot 162, the foot adjuster 164, and the wheeled foot 166 may be configured to directly or indirectly couple to the aperture 138 of the bottom shelf panel 120. Each foot adjuster 164 may be configured to facilitate height adjustment and leveling of the shelf assembly 101 during use. On an even ground or other surface, the flat foot 162 may provide a smooth surface on which the shelf assembly 101 may rest. Desirably, the foot adjuster 164 may allow the user to customize the leveling and height of the shelf assembly 101 on a level or unlevel ground or other surface by increasing or reducing a height of the foot assembly 112. In certain embodiments, the foot assembly 112 including the wheeled foot 166 may have a wheel 168 and a wheel lock mechanism 170. A connecting element 172 of the wheeled foot 166 may be configured to be received in the aperture 138 of the bottom shelf panel 120 using a friction fit or any other suitable connecting mechanism, as determined by a skilled artisan. The wheel 168 may allow the shelf assembly 101 to be easily transported and / or rolled to a desired location. The wheel lock mechanism 170 may be activated to militate against a rotation of the wheel 168 and facilitate maintaining the shelf assembly 101 in a desired location. One of ordinary skill in the art may select a suitable foot assembly 112 within the scope of the present disclosure. It should be appreciated that the foot assemblies 112 may be provided in the component carton 154 disposed in the hollow interior 104 and / or disposed in the hollow interior 104 outside of the component carton 154.

[0043] The wall securing mechanism 114 may be used to secure the shelf assembly 101 to a wall or wall-like structure for additional stability and storage capabilities. As an example, wall brackets may be utilized. It should be appreciated that one of ordinary skill in the art may select any suitable wall securing mechanism 114 having any desired configuration and connecting mechanism within the scope of the present disclosure.

[0044] The interlocking components 116 may be configured for insertion into an interlocking slot 174 formed in or adjacent to an outer edge 176 of one or more of the first panel member 126, the second panel member 128, and the third panel member 130 of each shelf panel 102. The interlocking slot 174 in combination with the interlocking component 116 may be utilized to couple one shelf panel 102 to another shelf panel 102. The interlocking component 116 may include a first interlocking section 178 configured to be received in the interlocking slot 174 of one shelf panel 102 and a second interlocking section 180 configured to be received in the interlocking slot 174 of another shelf panel 102 when the shelf panels 102 are positioned adjacent one another. Advantageously, the interlocking components 116 may enable multiple assembled shelf assemblies 101 to be coupled in each of a side-by-side and a back-to-back configuration, thereby creating expandable storage configurations.

[0045] In certain embodiments, the packaging assembly 100 may include additional components 106 such as one or more shelf dividers 118. Each shelf divider 118 may be configured to removably couple to a corresponding shelf panel 102 and may be disposed in the hollow interior 104 formed by the shelf panels 102 in the stacked configuration. Advantageously, the shelf divider 118 may enhance the structural integrity of each shelf panel 102 and the shelf assembly 101 as a whole. Additionally, the shelf divider 118 may allow the user to store additional storage totes 134 on each shelf panel 102. It should be appreciated that the shelf divider 118 may be included or not included in the packaging assembly 100 as desired, for example, based on user requirements, desired load carrying capacity, and materials and configurations selected to form the shelf assembly 101. It should be appreciated that the shelf dividers 118 may be housed in the component carton 154 disposed in the hollow interior 104 and / or in the hollow interior 104 outside of the component carton 154, as determined by a skilled artisan.

[0046] The additional components 106 such as the poles 108, top caps 110, foot assemblies 112, wall securing mechanism 114, interlocking components 116, and shelf dividers 118 may advantageously be disposed in the component carton 154 and / or in the hollow interior 104 outside of the component carton 154. In this way, the additional components 106 may be securely stored and transported in the hollow interior 104 formed by the shelf panels 102 in the stacked configuration. Desirably, the hollow interior 104 of the shelf panels 102 may allow for an efficient, organized packaging configuration that reduces shipping costs while militating against damage to the additional components 106 during transit and storage. Advantageously, the component carton 154 may further militate against loss and damage of one or more of the additional components 106 during shipping, transport, and storage of the packaging system 100, including storage in warehouses and retail environments.

[0047] In certain embodiments, as shown in FIGS. 5-7, the packaging system 100 may further include one or more storage totes 134 disposed in the hollow interior 104 of the shelf panels 102 in the stacked configuration. Each storage tote 134 may include an associated lid 182 configured to removably couple to the storage tote 134. It should be understood that the storage totes 134 and associated lids 182 may be disposed in the hollow interior 104 of the shelf panels 102 in the stacked configuration. The storage totes 134 and associated lids 182 may be configured to be suspended from the shelf panels 102 of the shelf assembly 101 during use. The storage totes 134 and associated lids 182 may have uniform and / or variable shapes, sizes, and configurations. In certain embodiments, each of the storage totes 134 and associated lids 182 may be the same size. It should be appreciated that two or more different sizes of storage totes 134 and associated lids 182 may be provided with the packaging system 100, where each of the two or more different sizes of storage totes 134 and associated lids 182 may include a width and / or a length configured to cooperate with the hollow interior 104 formed by the shelf panels 102 in the stacked configuration. The associated lids 182 may be arranged in a stacked configuration below and / or above the storage totes 134, as determined by one of skill in the art. The storage totes 134 may include a cross-sectional dimension disposed centrally and configured to fit within the hollow interior 104 of a plurality of shelf panels 102 including a bottom shelf panel 120, a top shelf panel 124, and at least one intermediate shelf panel 122.

[0048] With reference to FIGS. 6-7, a top storage tote 184 may be configured to form a hollow interior space 186 in which the additional components 106, such as the poles 108, the shelf dividers 118, and any additional components 106 disposed in the component carton 154 or outside of the component carton 154 may be housed during storage and transport of the packaging system 100. The top storage tote 184 may be configured to receive and to cooperate with a bottom lid 188 in a stacked lid configuration, thereby providing secure storage of the additional components 106 during shipping and storage and facilitating easy access thereto during assembly. It should also be understood that instructions, product information, promotional materials and the like may be disposed in the hollow interior space 186 of the top storage tote 184 and / or the hollow interior 104 formed by the shelf panels 102 of the packaging system 100.

[0049] The packaging system 100 may also include a material or a combination of materials (not shown), such as a wrap material and / or a protective material 194, disposed around at least a portion of the shelf panels 102 and / or the storage totes 134 and associated lids 182 to facilitate maintaining the shelf panels 102 in the stacked configuration and / or the storage totes 134 and associated lids 182 in a desired configuration independent of or in combination with the shelf panels 102. It should be appreciated that a material or a combination of materials (not shown), such as a wrap material and / or a protective material 194, may be disposed around at least a portion of one or more of the additional components 106 such as the poles 108, top caps 110, foot assemblies 112, wall securing mechanism 114, interlocking components 116, and shelf dividers 118. One or more of the additional components 106 and the material may be disposed in the component carton 154 and / or may be independent of the component carton 154. In certain embodiments, the material may be disposed on one or more of the additional components 106 and / or the component carton 154. The packaging system 100 may also include other protective elements such as foam inserts, carboard dividers, and / or bubble wrap, as examples, to militate against damage to the shelf panels 102, the storage totes 134 and associated lids 182, the additional components 106, and any other items included in the packaging system 100 during storage and transit.

[0050] The packaging system 100 may also include a container 192, such as a cardboard box, as an example. The shelf panels 102, the storage totes 134, and the associated lids 182 together with the additional components 106, the component cartons 154, and supporting literature, as examples, may be disposed in an interior of the container 192. The container 192 may facilitate retaining the shelf panels 102 in the stacked configuration and maintaining the storage totes 134, associated lids 182, additional components 106, component cartons 154, and supporting literature within the hollow interior 104 formed by the shelf panels 102 and / or the hollow interior space 186 of the top storage tote 184. It should be understood that the container 192 may be a cardboard box or corrugated cardboard box or any other suitable container, box, or box material, as determined by a skilled artisan. In embodiments that do not include the storage totes 134 and associated lids 182, it should be appreciated that the additional components 106, component cartons 154, and supporting literature may be disposed in the hollow interior 104 formed by the shelf panels 102 and may directly or indirectly rest on or be secured to an inside surface of the container 192.

[0051] With reference to FIG. 10, a method 200 of assembling the packaging system 100 is provided. The method 200 may include a step 202 of providing the packaging system 100 as described herein. The method 200 may include a step 204 of positioning the bottom shelf panel 120 as a base of the packaging system 100. A step 206 may include placing at least one intermediate shelf panel 122 on top of the bottom shelf panel 120, and a step 208 may include positioning the top shelf panel 124 on top of the intermediate shelf panel 122 to form the hollow interior 104 formed by the shelf panels 102 in the stacked configuration. The method 200 may include a step 210 of positioning the poles 108, the component carton 154 including additional components 106, and the foot assemblies 112 within the hollow interior 104 of the shelf panels 102.

[0052] With reference to FIG. 11, another method 300 of assembling the packaging system 100 is provided. The method 300 may include a step 302 of providing the packaging system 100 as described herein. The method 300 may include a step 304 of positioning the bottom shelf panel 120 as a base of the packaging system 100. A step 306 may include placing at least one intermediate shelf panel 122 on top of the bottom shelf panel 120, and a step 308 may include positioning the top shelf panel 124 on top of the at least one intermediate shelf panel 122 to form the hollow interior 104 formed by the shelf panels 102 in the stacked configuration. The method 300 may include a step 310 of positioning the storage totes 134 in the hollow interior 104 formed by the shelf panels 102 and a step 312 of positioning one or more of the poles 108, the additional components 106, the component carton 154 including additional components 106, and the foot assemblies 112, as examples, within the hollow interior space 186 of the top storage tote 184. The method 300 may further include a step 314 of positioning the associated lids 182 on the top storage tote 184. It should be appreciated that the method 300 may include securing a bottom lid 188 to the top storage tote 184, thereby securing the top storage tote 184 in a closed configuration.

[0053] Additional steps relating to selecting one or more desired lengths of the poles 108, selecting one or more desired foot assemblies 112, selecting a desired number of shelf dividers 118, and / or selecting a desired number and configuration of storage totes 134 and associated lids 182 may be included in one or more of the methods 200, 300, as examples. It should be appreciated that steps relating to selecting desired additional components 106 and packaging and / or securing the additional components in the component carton 154, the hollow interior 104, and / or the hollow interior space 186, may be included in one or more of the methods 200, 300. Steps relating to packaging the packaging system 100 in a container 192 and / or in any suitable material or a combination of materials and packaging the additional components 106 in the component carton 154 and / or in a material or a combination of materials may be included, as well as steps relating to securing one or more of the additional components 106 and the component carton 154 to the packaging system 100, the container 192, and / or a material or a combination of materials. It should be appreciated that steps may be omitted, added, and / or repeated, as determined by one of skill in the art.

[0054] The packaging system 100 may advantageously be configured to optimize space, reduce shipping, storage, and inventory costs, and enhance the user experience. The packaging system 100 may employ an efficient arrangement for the additional components 106 to allow the plurality of poles 108, the component carton 154, and the plurality of feet 112, as examples, to be stored within the hollow interior 104 of the shelf panels 102 in the stacked configuration and / or within the hollow interior space 186 of the top storage tote 184. The packaging system 100 may be configured to utilize simple connecting mechanisms such as snap fits so no specialized tools, or parts are required for assembly and use. Likewise, simple connecting mechanisms may allow for easily connecting one shelf assembly to another shelf assembly and allow for easily disassembling each shelf assembly without tools or specialized equipment. Advantageously, the additional components 106 such as the poles 108, top caps 110, foot assemblies 112, wall securing mechanisms 114, interlocking components 116, and shelf dividers 118 may be configured to fit in the hollow interior 104 or the hollow interior space 186. The storage totes 134, the associated lids 182, the components carton 154, and the additional components 106 may be configured to be positioned and / or secured within an outer perimeter 190 of the packaging system 100 defined by the shelf panels 102 in the stacked configuration, thereby allowing the shelf panels 102 to be placed in a container 192 of any suitable size, shape and configuration along with the storage totes 134, the associated lids 182, the components carton 154, and the additional components 106.

[0055] Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods can be made within the scope of the present technology, with substantially similar results.

Examples

Embodiment Construction

[0026]The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments, including where certain steps can be simultaneously performed, unless expressly stated otherwise. “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 772,897, filed on Mar. 17, 2025. The entire disclosure of the above application is incorporated herein by reference.FIELD

[0002] The present technology relates to modular storage systems, and more particularly, to a configurable shelf assembly and related packaging for efficient shipping, storage, and user assembly.INTRODUCTION

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Shelf systems often utilize a fixed configuration, limiting the adaptability of shelf systems with respect to different spaces and user needs. The lack of flexibility may present challenges in modern living environments where space optimization is necessary and / or preferred. Additionally, an inability to easily reconfigure or expand the shelf systems may lead to premature replacement of the shelf systems, contributing to unnecessary waste. Fixed configurations may also lead to inefficient packing and shipping of the shelf systems as the packaging containers may need to be adjusted or modified to conform to the shelf systems, thereby increasing packaging costs.

[0005] Modular storage systems, particularly configurable shelf assemblies, can be versatile and adaptable to various living and storage spaces. However, shipping, storage, and assembly of configurable shelf assemblies may present unique challenges compared to fixed shelf assemblies. For example, a configurable shelf assembly may include multiple components that are shipped separately, leading to increased packaging materials and waste, as well as increased shipping, storage, and inventory management costs. Separate shipping may also increase the risk of components being lost or damaged during transit and the risk of the end user receiving the wrong components.

[0006] For configurable shelf assemblies shipped as a single unit, suboptimal arrangement and packaging of various components may result in damaged pieces and parts. For example, suboptimal packaging may result in a heavier component damaging a smaller component during packing or transport. What is more, common materials used for configurable shelf assemblies are often excessively heavy when packaged together and, as a result, difficult for the end user to lift and move. Heavy materials and components may also result in increased shipping costs, thereby decreasing profit for the manufacturer and / or increasing the cost for the end user.

[0007] Configurable shelf assemblies often also include confusing, hard to follow assembly instructions such as text-heavy manuals or complex diagrams. Complex instructions may leave the end user confused and frustrated during assembly and may result in the product being assembled incorrectly. Assembly errors may compromise operation of the product, thereby affecting the quality and safety of the configurable shelf assembly. Additional tools required for assembly and installation of configurable shelf assemblies may also be required, further complicating the assembly process for the end user.

[0008] Accordingly, there is a continuing need for a configurable shelf assembly system that addresses challenges with respect to shipping, storage, and assembly of the configurable shelf assembly. Desirably, such a system may be configured for efficient packaging for reduced shipping, storage, and inventory management costs, provide clear and intuitive assembly instructions, allow for easy reconfiguration and expansion, utilize lightweight yet durable materials, and maintain stability and structural integrity throughout the shipping and assembly process.SUMMARY

[0009] In concordance with the instant disclosure, a configurable shelf assembly system that is configured for efficient packaging for reduced shipping, storage, and inventory management costs, provides clear and intuitive assembly instructions, allows for easy reconfiguration and expansion, utilizes lightweight yet durable materials, and maintains stability and structural integrity throughout the shipping and assembly process, has surprisingly been discovered. The present technology includes articles of manufacture, systems, and processes that relate to modular storage systems, and more particularly, to configurable shelf assemblies and related packaging configured for efficient and organized shipping, storage, and user assembly.

[0010] In certain embodiments, a packaging system for a shelf assembly may include a plurality of shelf panels arranged in a stacked configuration. The plurality of shelf panels may include a bottom shelf panel, a top shelf panel, and at least one intermediate shelf panel. The plurality of shelf panels may form a hollow interior. The packaging system may include a plurality of poles positioned within the hollow interior and a plurality of additional components positioned within the hollow interior.

[0011] In certain embodiments, a method of assembling a packaging system for a shelf assembly may include a first step of providing a plurality of shelf panels arranged in a stacked configuration. The plurality of shelf panels may include a bottom shelf panel, a top shelf panel, and at least one intermediate shelf panel. The plurality of shelf panels may form a hollow interior. The packaging system may include a plurality of poles and a plurality of additional components. Steps including positioning the bottom shelf panel as a base of the packaging system, placing the at least one intermediate shelf panel on top of the bottom shelf panel, and positioning the top shelf panel on top of the at least one intermediate shelf panel may be included. Each of the bottom shelf panel, the at least one intermediate shelf panel, and the top shelf panel may be positioned in a stacked configuration and may form the hollow interior. The method may further include positioning the plurality of poles and the plurality of additional components within the hollow interior.

[0012] In certain embodiments, a method of assembling a packaging system for a shelf assembly may include a first step of providing a plurality of shelf panels arranged in a stacked configuration. The plurality of shelf panels may include a bottom shelf panel, a top shelf panel, and at least one intermediate shelf panel. The plurality of shelf panels may form a hollow interior. The packaging system may include a plurality of poles, a plurality of additional components, and a plurality of storage totes. Additional steps may include positioning the bottom shelf panel as a base of the packaging system, placing the at least one intermediate shelf panel on top of the bottom shelf panel, and positioning the top shelf panel on top of the at least one intermediate shelf panel. Each of the bottom shelf panel, the at least one intermediate shelf panel, and the top shelf panel may be positioned in a stacked configuration and may form the hollow interior. A step of positioning the plurality of storage totes in the hollow interior may be included in the method. A top storage tote of the plurality of storage totes may have a hollow interior space. A step including positioning the plurality of poles and the plurality of additional components within the hollow interior space of the top storage tote may also be included.

[0013] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.DRAWINGS

[0014] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure.

[0015] FIG. 1 is a top perspective view of a packaging system for a shelf assembly, according to an embodiment of the present disclosure;

[0016] FIG. 2 is a top plan view thereof;

[0017] FIG. 3 is a top perspective view of additional components and a component carton of a packaging system for a shelf assembly, according to an embodiment of the present disclosure;

[0018] FIG. 4 is a top perspective view of a packaging system for a shelf assembly, according to an embodiment of the present disclosure;

[0019] FIG. 5 is a top perspective view of a packaging system for a shelf assembly including totes and lids, according to an embodiment of the present disclosure;

[0020] FIG. 6 is top perspective view thereof shown without the lids;

[0021] FIG. 7 is a partially exploded top perspective view thereof;

[0022] FIG. 8 is a schematic block diagram illustrating a packaging system for a shelf assembly, according to an embodiment of the present disclosure;

[0023] FIG. 9 is a schematic block diagram illustrating a packaging system for a shelf assembly, according to an embodiment of the present disclosure;

[0024] FIG. 10 is a schematic block diagram illustrating a method of assembling a packaging system for a shelf assembly, according to an embodiment of the present disclosure; and

[0025] FIG. 11 is a schematic block diagram of a method of assembling a packaging system for a shelf assembly, according to an embodiment of the present disclosure.DETAILED DESCRIPTION

[0026] The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments, including where certain steps can be simultaneously performed, unless expressly stated otherwise. “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “substantially” in describing the broadest scope of the technology. “About” when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” and / or “substantially” is not otherwise understood in the art with this ordinary meaning, then “about” and / or “substantially” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters.

[0027] Although the open-ended term “comprising,” as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments may alternatively be described using more limiting terms such as “consisting of” or “consisting essentially of.” Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or process steps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that may be recited in the art, even though element D is not explicitly described as being excluded herein.

[0028] As referred to herein, disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of “from A to B” or “from about A to about B” is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter may define endpoints for a range of values that may be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of 1–10, or 2–9, or 3–8, it is also envisioned that Parameter X may have other ranges of values including 1–9, 1–8, 1–3, 1–2, 2–10, 2–8, 2–3, 3–10, 3–9, and so on.

[0029] When an element or layer is referred to as being “on,”“engaged to,”“connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,”“directly engaged to,”“directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,”“adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0030] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,”“second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0031] Spatially relative terms, such as “inner,”“outer,”“beneath,”“below,”“lower,”“above,”“upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0032] The present technology improves shipping, storage, and assembly of modular storage systems. Specifically, the present technology militates against increased packaging materials and shipping costs due to separately shipped components, inefficient packaging, and heavy components. The present technology further militates against risk of lost or damaged parts during transit, confusing assembly instructions, and complex and time-consuming assembly processes.

[0033] With reference to FIGS. 1-9, a packaging system 100 for a shelf assembly 101 is shown. The packaging system 100 may include one or more shelf panels 102 arranged in a stacked configuration. The shelf panels 102 arranged in the stacked configuration may form a hollow interior 104. It should be appreciated that an entirety of a plurality of the shelf panels 102 in a stacked configuration may form the hollow interior 104. As an example, as shown in FIG. 1, a plurality of five shelf panels 102 may collectively form the hollow interior 104. Advantageously, the hollow interior 104 formed by the shelf panels 102 may be used to store additional components 106 of the packaging system 100, such as one or more poles 108, top caps 110, foot assemblies 112, wall securing mechanisms 114, interlocking components 116, and shelf dividers 118, to optimize efficient packaging of the shelf assembly 101, reduce shipping, storage, and inventory costs, and militate against the risk of lost or damaged components during transportation. Desirably, the packaging system 100 may provide a user with every component necessary to assemble the shelf assembly 101 in a desired configuration without the need for specialized tools and equipment.

[0034] The shelf panels 102 may include a bottom shelf panel 120, at least one intermediate shelf panel 122, and a top shelf panel 124. The bottom shelf panel 120 may be configured as a base and may be positioned at the bottom of the packaging system 100. The shelf panels 102 may be formed from lightweight materials such as polypropylene plastic. The shelf panels 102 may alternatively be formed of other materials such as polyethylene, foam, or metal. One of ordinary skill in the art may select a suitable material or combination of materials to form the shelf panels 102 within the scope of the present disclosure.

[0035] Each shelf panel 102 may include a first panel member 126, a second panel member 128, a third panel member 130, and a cross member 132 configured to form a portion of the hollow interior 104. Each shelf panel 102 may be configured to facilitate the insertion and sliding of a storage tote 134 for suspension from the shelf panel 102 in the assembled shelf assembly 101. In certain embodiments, one or more of the shelf panels 102 may include the first panel member 126, the second panel member 128, and the third panel member 130, and may not include the cross member 132. The cross member 132 may be configured to enhance the structural integrity of the shelf panel 102 and may be included or not included in selected ones or all of the shelf panels 102 as desired, for example, based on user requirements, desired load carrying capacity, and materials selected to form the shelf panels 102.

[0036] Each of the first panel member 126, the second panel member 128, the third panel member 130, and the cross member 132 may be an elongated member and may have any suitable size, shape, and configuration, such as a rectangular cross sectional shape, as an example. Each shelf panel 102 may include support ribs 136 disposed on a bottom surface and may be configured to enhance the structural integrity of each shelf panel 102 and the packaging system 100 when the shelf panels 102 are arranged in the stacked configuration. It should be appreciated that the support ribs 136 of one shelf panel 102 may be configured to abut a shelf panel 102 disposed directly underneath.

[0037] Each shelf panel 102 may include one or more apertures 138 disposed therethrough, as shown in FIGS. 1 and 4. In certain embodiments, apertures 138 may be disposed adjacent each corner 140 of the shelf panel 102 and / or adjacent a section of the shelf panel 102 where any two of the first panel member 126, the second panel member 128, the third panel member 130, and the cross member 132 come together. One of ordinary skill in the art may select any suitable shape, size, and configuration for the aperture 138 within the scope of the present disclosure. It should be appreciated that any suitable structural elements configured to facilitate assembly and enhance stability may be included, as determined by a skilled artisan.

[0038] The packaging system 100 may include additional components 106 such as one or more poles 108. Each pole 108 may be elongated and may be configured for insertion into one or more apertures 138 of the shelf panels 102. The poles 108 may be uniform in length and / or may have variable lengths. In certain embodiments, a first set of poles 142 may have a first uniform length 146, and a second set of poles 144 may have a second uniform length 148 that is different from the first uniform length 146 of the first set of poles 142, thereby providing variable distances between successive shelf panels 102 in the assembled shelf assembly 101.

[0039] The poles 108 may be configured to couple and stack each of the shelf panels 102 to one another. It should be appreciated that the poles 108 may be configured to provide any desired spacing between two successive shelf panels 102, as determined by a skilled artisan. Advantageously, the poles 108 may be configured to fit in the hollow interior 104 formed by the shelf panels 102 during storage and transport of the packaging system 100. The length of each pole 108 may be selected to provide a desired distance between successive shelf panels 102 and to fit within the hollow interior 104. The poles 108 may include fixed, rigid poles 108, telescoping poles 108, and / or any other suitable poles 108, as desired. In certain embodiments, at least one end 150 of each pole 108 may include an insertion portion 152 configured to be received by the aperture 138. It should be appreciated that the poles 108 may be individually included in the hollow interior 104, secured to one another, and / or secured to the shelf panels 102 and / or additional components 106 of the packaging system 100. A protective wrap 194 and / or other material, such as bubble wrap or cardboard, may be used to militate against damage to the poles 108 during transport of the packaging system 100.

[0040] The packaging system 100 may also include a component carton 154 configured to include one or more of the additional components 106 of the packaging system 100. As shown in FIGS. 1 and 3, the component carton 154 may include additional components 106 such as one or more top caps 110, foot assemblies 112, wall securing mechanisms 114, and interlocking components 116, as examples. Each of the additional components 106 may be stored in the component carton 154 during transport. The component carton 154 may be fabricated using any material or combination of materials such as cardboard or plastic, as examples, and may include a padding material such as bubble wrap or packing paper, as examples. Any suitable shape, size, and configuration may be used to form the component carton 154. In certain embodiments, more than one component carton 154 may be included in the packaging system 100. Advantageously, the component carton 154 may be a size, shape, and configuration capable of housing the additional components 106 in such a way as to militate against movement of and damage to the additional components 106. In certain embodiments, the poles 108 and / or the shelf dividers 118 may be included in the component carton 154, as determined by one of skill in the art.

[0041] The top caps 110 may be configured to be received in the apertures 138 formed in the top shelf panel 124. Each top cap 110 may include a top portion 156 and a bottom portion 158. The bottom portion 158 may be configured to be received in the aperture 138 of the top shelf panel 124 and the top portion 156 may abut a top surface 160 of the top shelf panel 124, thereby covering the aperture 138. The bottom portion 158 may be configured to be removably secured in the aperture 138 using a friction fit, a snap fit, a threaded fit, or any other suitable connecting mechanism. One of ordinary skill in the art may select any suitable top cap 110 within the scope of the present disclosure.

[0042] The foot assemblies 112 may include one or more of a flat foot 162, a foot adjuster 164 configured to cooperate with and couple to the flat foot 162, and a wheeled foot 166. Each of the flat foot 162, the foot adjuster 164, and the wheeled foot 166 may be configured to directly or indirectly couple to the aperture 138 of the bottom shelf panel 120. Each foot adjuster 164 may be configured to facilitate height adjustment and leveling of the shelf assembly 101 during use. On an even ground or other surface, the flat foot 162 may provide a smooth surface on which the shelf assembly 101 may rest. Desirably, the foot adjuster 164 may allow the user to customize the leveling and height of the shelf assembly 101 on a level or unlevel ground or other surface by increasing or reducing a height of the foot assembly 112. In certain embodiments, the foot assembly 112 including the wheeled foot 166 may have a wheel 168 and a wheel lock mechanism 170. A connecting element 172 of the wheeled foot 166 may be configured to be received in the aperture 138 of the bottom shelf panel 120 using a friction fit or any other suitable connecting mechanism, as determined by a skilled artisan. The wheel 168 may allow the shelf assembly 101 to be easily transported and / or rolled to a desired location. The wheel lock mechanism 170 may be activated to militate against a rotation of the wheel 168 and facilitate maintaining the shelf assembly 101 in a desired location. One of ordinary skill in the art may select a suitable foot assembly 112 within the scope of the present disclosure. It should be appreciated that the foot assemblies 112 may be provided in the component carton 154 disposed in the hollow interior 104 and / or disposed in the hollow interior 104 outside of the component carton 154.

[0043] The wall securing mechanism 114 may be used to secure the shelf assembly 101 to a wall or wall-like structure for additional stability and storage capabilities. As an example, wall brackets may be utilized. It should be appreciated that one of ordinary skill in the art may select any suitable wall securing mechanism 114 having any desired configuration and connecting mechanism within the scope of the present disclosure.

[0044] The interlocking components 116 may be configured for insertion into an interlocking slot 174 formed in or adjacent to an outer edge 176 of one or more of the first panel member 126, the second panel member 128, and the third panel member 130 of each shelf panel 102. The interlocking slot 174 in combination with the interlocking component 116 may be utilized to couple one shelf panel 102 to another shelf panel 102. The interlocking component 116 may include a first interlocking section 178 configured to be received in the interlocking slot 174 of one shelf panel 102 and a second interlocking section 180 configured to be received in the interlocking slot 174 of another shelf panel 102 when the shelf panels 102 are positioned adjacent one another. Advantageously, the interlocking components 116 may enable multiple assembled shelf assemblies 101 to be coupled in each of a side-by-side and a back-to-back configuration, thereby creating expandable storage configurations.

[0045] In certain embodiments, the packaging assembly 100 may include additional components 106 such as one or more shelf dividers 118. Each shelf divider 118 may be configured to removably couple to a corresponding shelf panel 102 and may be disposed in the hollow interior 104 formed by the shelf panels 102 in the stacked configuration. Advantageously, the shelf divider 118 may enhance the structural integrity of each shelf panel 102 and the shelf assembly 101 as a whole. Additionally, the shelf divider 118 may allow the user to store additional storage totes 134 on each shelf panel 102. It should be appreciated that the shelf divider 118 may be included or not included in the packaging assembly 100 as desired, for example, based on user requirements, desired load carrying capacity, and materials and configurations selected to form the shelf assembly 101. It should be appreciated that the shelf dividers 118 may be housed in the component carton 154 disposed in the hollow interior 104 and / or in the hollow interior 104 outside of the component carton 154, as determined by a skilled artisan.

[0046] The additional components 106 such as the poles 108, top caps 110, foot assemblies 112, wall securing mechanism 114, interlocking components 116, and shelf dividers 118 may advantageously be disposed in the component carton 154 and / or in the hollow interior 104 outside of the component carton 154. In this way, the additional components 106 may be securely stored and transported in the hollow interior 104 formed by the shelf panels 102 in the stacked configuration. Desirably, the hollow interior 104 of the shelf panels 102 may allow for an efficient, organized packaging configuration that reduces shipping costs while militating against damage to the additional components 106 during transit and storage. Advantageously, the component carton 154 may further militate against loss and damage of one or more of the additional components 106 during shipping, transport, and storage of the packaging system 100, including storage in warehouses and retail environments.

[0047] In certain embodiments, as shown in FIGS. 5-7, the packaging system 100 may further include one or more storage totes 134 disposed in the hollow interior 104 of the shelf panels 102 in the stacked configuration. Each storage tote 134 may include an associated lid 182 configured to removably couple to the storage tote 134. It should be understood that the storage totes 134 and associated lids 182 may be disposed in the hollow interior 104 of the shelf panels 102 in the stacked configuration. The storage totes 134 and associated lids 182 may be configured to be suspended from the shelf panels 102 of the shelf assembly 101 during use. The storage totes 134 and associated lids 182 may have uniform and / or variable shapes, sizes, and configurations. In certain embodiments, each of the storage totes 134 and associated lids 182 may be the same size. It should be appreciated that two or more different sizes of storage totes 134 and associated lids 182 may be provided with the packaging system 100, where each of the two or more different sizes of storage totes 134 and associated lids 182 may include a width and / or a length configured to cooperate with the hollow interior 104 formed by the shelf panels 102 in the stacked configuration. The associated lids 182 may be arranged in a stacked configuration below and / or above the storage totes 134, as determined by one of skill in the art. The storage totes 134 may include a cross-sectional dimension disposed centrally and configured to fit within the hollow interior 104 of a plurality of shelf panels 102 including a bottom shelf panel 120, a top shelf panel 124, and at least one intermediate shelf panel 122.

[0048] With reference to FIGS. 6-7, a top storage tote 184 may be configured to form a hollow interior space 186 in which the additional components 106, such as the poles 108, the shelf dividers 118, and any additional components 106 disposed in the component carton 154 or outside of the component carton 154 may be housed during storage and transport of the packaging system 100. The top storage tote 184 may be configured to receive and to cooperate with a bottom lid 188 in a stacked lid configuration, thereby providing secure storage of the additional components 106 during shipping and storage and facilitating easy access thereto during assembly. It should also be understood that instructions, product information, promotional materials and the like may be disposed in the hollow interior space 186 of the top storage tote 184 and / or the hollow interior 104 formed by the shelf panels 102 of the packaging system 100.

[0049] The packaging system 100 may also include a material or a combination of materials (not shown), such as a wrap material and / or a protective material 194, disposed around at least a portion of the shelf panels 102 and / or the storage totes 134 and associated lids 182 to facilitate maintaining the shelf panels 102 in the stacked configuration and / or the storage totes 134 and associated lids 182 in a desired configuration independent of or in combination with the shelf panels 102. It should be appreciated that a material or a combination of materials (not shown), such as a wrap material and / or a protective material 194, may be disposed around at least a portion of one or more of the additional components 106 such as the poles 108, top caps 110, foot assemblies 112, wall securing mechanism 114, interlocking components 116, and shelf dividers 118. One or more of the additional components 106 and the material may be disposed in the component carton 154 and / or may be independent of the component carton 154. In certain embodiments, the material may be disposed on one or more of the additional components 106 and / or the component carton 154. The packaging system 100 may also include other protective elements such as foam inserts, carboard dividers, and / or bubble wrap, as examples, to militate against damage to the shelf panels 102, the storage totes 134 and associated lids 182, the additional components 106, and any other items included in the packaging system 100 during storage and transit.

[0050] The packaging system 100 may also include a container 192, such as a cardboard box, as an example. The shelf panels 102, the storage totes 134, and the associated lids 182 together with the additional components 106, the component cartons 154, and supporting literature, as examples, may be disposed in an interior of the container 192. The container 192 may facilitate retaining the shelf panels 102 in the stacked configuration and maintaining the storage totes 134, associated lids 182, additional components 106, component cartons 154, and supporting literature within the hollow interior 104 formed by the shelf panels 102 and / or the hollow interior space 186 of the top storage tote 184. It should be understood that the container 192 may be a cardboard box or corrugated cardboard box or any other suitable container, box, or box material, as determined by a skilled artisan. In embodiments that do not include the storage totes 134 and associated lids 182, it should be appreciated that the additional components 106, component cartons 154, and supporting literature may be disposed in the hollow interior 104 formed by the shelf panels 102 and may directly or indirectly rest on or be secured to an inside surface of the container 192.

[0051] With reference to FIG. 10, a method 200 of assembling the packaging system 100 is provided. The method 200 may include a step 202 of providing the packaging system 100 as described herein. The method 200 may include a step 204 of positioning the bottom shelf panel 120 as a base of the packaging system 100. A step 206 may include placing at least one intermediate shelf panel 122 on top of the bottom shelf panel 120, and a step 208 may include positioning the top shelf panel 124 on top of the intermediate shelf panel 122 to form the hollow interior 104 formed by the shelf panels 102 in the stacked configuration. The method 200 may include a step 210 of positioning the poles 108, the component carton 154 including additional components 106, and the foot assemblies 112 within the hollow interior 104 of the shelf panels 102.

[0052] With reference to FIG. 11, another method 300 of assembling the packaging system 100 is provided. The method 300 may include a step 302 of providing the packaging system 100 as described herein. The method 300 may include a step 304 of positioning the bottom shelf panel 120 as a base of the packaging system 100. A step 306 may include placing at least one intermediate shelf panel 122 on top of the bottom shelf panel 120, and a step 308 may include positioning the top shelf panel 124 on top of the at least one intermediate shelf panel 122 to form the hollow interior 104 formed by the shelf panels 102 in the stacked configuration. The method 300 may include a step 310 of positioning the storage totes 134 in the hollow interior 104 formed by the shelf panels 102 and a step 312 of positioning one or more of the poles 108, the additional components 106, the component carton 154 including additional components 106, and the foot assemblies 112, as examples, within the hollow interior space 186 of the top storage tote 184. The method 300 may further include a step 314 of positioning the associated lids 182 on the top storage tote 184. It should be appreciated that the method 300 may include securing a bottom lid 188 to the top storage tote 184, thereby securing the top storage tote 184 in a closed configuration.

[0053] Additional steps relating to selecting one or more desired lengths of the poles 108, selecting one or more desired foot assemblies 112, selecting a desired number of shelf dividers 118, and / or selecting a desired number and configuration of storage totes 134 and associated lids 182 may be included in one or more of the methods 200, 300, as examples. It should be appreciated that steps relating to selecting desired additional components 106 and packaging and / or securing the additional components in the component carton 154, the hollow interior 104, and / or the hollow interior space 186, may be included in one or more of the methods 200, 300. Steps relating to packaging the packaging system 100 in a container 192 and / or in any suitable material or a combination of materials and packaging the additional components 106 in the component carton 154 and / or in a material or a combination of materials may be included, as well as steps relating to securing one or more of the additional components 106 and the component carton 154 to the packaging system 100, the container 192, and / or a material or a combination of materials. It should be appreciated that steps may be omitted, added, and / or repeated, as determined by one of skill in the art.

[0054] The packaging system 100 may advantageously be configured to optimize space, reduce shipping, storage, and inventory costs, and enhance the user experience. The packaging system 100 may employ an efficient arrangement for the additional components 106 to allow the plurality of poles 108, the component carton 154, and the plurality of feet 112, as examples, to be stored within the hollow interior 104 of the shelf panels 102 in the stacked configuration and / or within the hollow interior space 186 of the top storage tote 184. The packaging system 100 may be configured to utilize simple connecting mechanisms such as snap fits so no specialized tools, or parts are required for assembly and use. Likewise, simple connecting mechanisms may allow for easily connecting one shelf assembly to another shelf assembly and allow for easily disassembling each shelf assembly without tools or specialized equipment. Advantageously, the additional components 106 such as the poles 108, top caps 110, foot assemblies 112, wall securing mechanisms 114, interlocking components 116, and shelf dividers 118 may be configured to fit in the hollow interior 104 or the hollow interior space 186. The storage totes 134, the associated lids 182, the components carton 154, and the additional components 106 may be configured to be positioned and / or secured within an outer perimeter 190 of the packaging system 100 defined by the shelf panels 102 in the stacked configuration, thereby allowing the shelf panels 102 to be placed in a container 192 of any suitable size, shape and configuration along with the storage totes 134, the associated lids 182, the components carton 154, and the additional components 106.

[0055] Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods can be made within the scope of the present technology, with substantially similar results.

Examples

Embodiment Construction

[0026]The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments, including where certain steps can be simultaneously performed, unless expressly stated otherwise. “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “...

Claims

1. A packaging system for a shelf assembly, comprising:a plurality of shelf panels arranged in a stacked configuration, the plurality of shelf panels including a bottom shelf panel, a top shelf panel, and at least one intermediate shelf panel, the plurality of shelf panels forming a hollow interior;a plurality of poles positioned within the hollow interior; anda plurality of additional components positioned within the hollow interior.

2. The packaging system of claim 1, wherein each shelf panel of the plurality of shelf panels includes a first panel member, a second panel member, a third panel member, and a cross member.

3. The packaging system of claim 1, wherein at least one component carton including one or more additional components of the plurality of additional components is positioned within the hollow interior.

4. The packaging system of claim 1, wherein a plurality of foot assemblies is positioned within the hollow interior.

5. The packaging system of claim 4, wherein each foot assembly of the plurality of foot assemblies includes a wheeled foot.

6. The packaging system of claim 4, wherein each foot assembly of the plurality of foot assemblies includes a flat foot and a foot adjuster configured to cooperate with the flat foot.

7. The packaging system of claim 1, wherein the plurality of additional components includes one or more of a top cap, a foot assembly, an interlocking component, and a wall securing mechanism.

8. The packaging system of claim 1, wherein at least one shelf divider is positioned in the hollow interior.

9. The packaging system of claim 1, further including a plurality of storage totes disposed in the hollow interior.

10. The packaging system of claim 9, further including a plurality of associated lids configured to couple to the plurality of storage totes.

11. The packaging system of claim 9, wherein a top storage tote of the plurality of storage totes includes a hollow interior space configured to hold the plurality of poles and the plurality of additional components.

12. The packaging system of claim 1, further including a protective material disposed around at least a portion of the plurality of shelf panels to facilitate maintaining the plurality of shelf panels in the stacked configuration and maintaining the plurality of poles and the plurality of additional components within the hollow interior.

13. The packaging system of claim 1, further including a container configured to receive the plurality of shelf panels, the plurality of poles, and the plurality of additional components.

14. The packaging system of claim 3, wherein the component compartment includes a plurality of top caps, a plurality of foot assemblies, a plurality of interlocking components, and a plurality of wall securing mechanisms.

15. A method of assembling a packaging system for a shelf assembly, comprising:providing a plurality of shelf panels arranged in a stacked configuration, the plurality of shelf panels including a bottom shelf panel, a top shelf panel, and at least one intermediate shelf panel, the plurality of shelf panels forming a hollow interior, a plurality of poles, and a plurality of additional components;positioning the bottom shelf panel as a base of the packaging system;placing the at least one intermediate shelf panel on top of the bottom shelf panel;positioning the top shelf panel on top of the at least one intermediate shelf panel, each of the bottom shelf panel, the at least one intermediate shelf panel, and the top shelf panel positioned in a stacked configuration and forming the hollow interior; andpositioning the plurality of poles and the plurality of additional components within the hollow interior.

16. The method of claim 15, further including providing at least one component carton positioned within the hollow interior.

17. The method of claim 15, wherein the plurality of additional components includes one or more of a top cap, a foot assembly, an interlocking component, and a wall securing mechanism.

18. A method of assembling a packaging system for a shelf assembly, comprising:providing a plurality of shelf panels arranged in a stacked configuration, the plurality of shelf panels including a bottom shelf panel, a top shelf panel, and at least one intermediate shelf panel, the plurality of shelf panels forming a hollow interior, a plurality of poles, a plurality of additional components, and a plurality of storage totes;positioning the bottom shelf panel as a base of the packaging system;placing the at least one intermediate shelf panel on top of the bottom shelf panel;positioning the top shelf panel on top of the at least one intermediate shelf panel, each of the bottom shelf panel, the at least one intermediate shelf panel, and the top shelf panel positioned in a stacked configuration and forming the hollow interior;positioning the plurality of storage totes in the hollow interior, a top storage tote of the plurality of storage totes having a hollow interior space; andpositioning the plurality of poles and the plurality of additional components within the hollow interior space of the top storage tote.

19. The method of claim 18, wherein the plurality of storage totes includes a plurality of associated lids.

20. The method of claim 18, further including securing a bottom lid of the plurality of associated lids to a top storage tote of the plurality of storage totes.

Images