Abstract:
A carrier tray having a plurality of compartments separated by a plurality of dividers. Each carrier tray has a plurality of stacking pins on a top portion and a plurality of pin holes on a bottom portion. Each stacking pin is located in an area approximately adjacent to each pin hole such that, for a given set of a stacking pin and a pin hole, the stacking pin is slightly offset relative to the pin hole. When stacking the carrier trays to form a stacked configuration of carrier trays, each carrier tray is rotated 180° relative to a carrier tray immediately below and a carrier tray immediately above the carrier tray.

Description:
CLAIM OF PRIORITY UNDER 35 U.S.C. §119 
       [0001]    The present Utility application for Patent claims priority to U.S. Provisional Application No. 61/014,637 entitled “Carrier Tray” filed Dec. 18, 2007, and hereby expressly incorporated by reference herein. 
     
    
     FIELD 
       [0002]    The present invention relates to the field of containers, in particular, to stackable or nestable carrier trays for storage and transportation of items such as food. 
       BACKGROUND OF THE INVENTION 
       [0003]    Produce shipping flats or open top containers or carrier trays are used to store and transport fresh and chilled foods, such as fruit, for selling to consumers. Typically, two or more containers are often stacked. Stacked carrier trays are carried manually or gathered by machinery, and are stacked in a storage area or on a pallet or the like to form a compact arrangement for storage or shipping. The stack can have any number of adjacent carrier trays. The individual carrier trays are arranged in vertical columns. Stacking maximizes density for storage, and often enables a group of carrier trays to be handled conveniently as a discrete unit, e.g., using a fork-lift truck or two wheel hand dolly. Separate containers, with food, are placed in a carrier tray so that one carrier tray may hold one or more separate containers of food. 
         [0004]    Conventional carrier trays are made from corrugated box material. The high humidity and rain that the carrier trays are exposed to often weaken the carrier trays. To overcome this problem, manufacturers “wax coat” the carrier trays so that they withstand the effects of the water and humidity. However, the wax coating applied to the shipping flats renders them un-recyclable. Furthermore, it is possible that the wax may be transferred to the contents within the trays, i.e., produce, and some consumers may object to this is a compromise of the quality of the produce. 
         [0005]    Furthermore, in humid environments, the conventional carrier trays made from corrugated material do not provide sufficient sidewall structure, yet maintain the required overall unit strength, to allow for rapid cooling of to the contents of the flat. Typically small “mouse holes” are punched from areas of the carrier tray which allows some air flow through the product, but generally not enough for rapid cooling. 
         [0006]    Furthermore, due to the construction of such conventional carrier trays, the contents therein may not be easily identifiable. This may render it difficult to quickly screen out expired fruit which cannot be sold to consumers. 
         [0007]    Consequently, a carrier tray which alleviates the problems of conventional carrier trays as discussed previously is needed. 
       SUMMARY OF THE INVENTION 
       [0008]    A carrier tray, including a plurality of compartments separated by a plurality of divider walls is herein disclosed. The plurality of compartments may include (i) a plurality of bottom surfaces; (ii) a plurality of outer sidewalls and a plurality of outer end walls extending continuously upwardly from the bottom surfaces, wherein each outer end wall includes at least one radially projecting protrusion projecting inwardly toward a compartment and at least one longitudinal concave groove adjacent to each radially projecting protrusion; (iii) a plurality of stacking pins wherein each stacking pin is located on a top surface of each radially projecting protrusion; and (iv) a plurality of pin holes wherein each pin hole is located on a bottom surface of each longitudinal concave groove. 
         [0009]    The carrier tray may be approximately rectangular in configuration and each compartment may be approximately rectangular in configuration. The carrier tray may further include at least two peripheral guide pads, each peripheral guide pad positioned in adjacent compartments along a length of the rectangular carrier tray, each peripheral guide pad located at an end corner where an outer end wall and an outer sidewall of a compartment meet. The plurality of divider walls may include a first divider wall, a second divider wall and a third divider wall, the first divider wall extending across a width of the carrier tray and centered thereto, the second divider wall extending across one-half of a length of the carrier tray and centered thereto, the third divider wall extending across one-half of the length of the carrier tray opposite to the second divider and centered thereto. 
         [0010]    The carrier tray may further include a plurality of corner stiffening gussets positioned at corners where the second divider wall meets the first divider wall and the third divider wall meets the first divider wall for adding corner strength to the plurality of compartments. The carrier tray may further include a plurality of inner guide pads located along the first divider. The plurality of divider walls may include a plurality of concave grooves. The plurality of divider walls may define a gap underneath. The carrier tray may further include (i) a flange integrally connected to, and outwardly projecting from, a perimeter of the plurality of outer sidewalls and the plurality of outer end walls of the carrier tray; and (ii) a plurality of reinforcing gussets positioned about the flange approximate to an area where outer ends of the plurality of dividers meet an inner peripheral wall of the carrier tray. The carrier tray may further include a plurality of ribs about the perimeter of the plurality of outer side walls, the plurality of outer end walls and the plurality of bottom surfaces of the compartments. The carrier tray may further include a plurality of depressions about the flange. The carrier tray may further include a plurality of apertures on the bottom surfaces of the compartments. The plurality of stacking pins and the plurality of pins holes may be offset relative to one another such that when placing a subsequent carrier tray on top of the carrier tray, the subsequent carrier tray is rotated 180° relative to the carrier tray. The carrier tray may be of a material comprising one of polyethylene terephthalate (PET), polystyrene or polypropylenes. 
         [0011]    A stacked carrier tray configuration, including: (i) a plurality of carrier trays stacked together wherein, for a given carrier tray, the carrier tray is offset from a carrier tray immediately below and a carrier tray immediately above the carrier tray; and (ii) a plurality of stacking pins on a plurality of top surfaces of each carrier tray and a plurality of pin holes on a plurality of bottom surfaces of each carrier tray wherein, for a given carrier tray, the plurality of stacking pins and the plurality of pin holes are offset relative to one another is herein disclosed. A ventilation gap may be formed between each carrier tray of the stacked carrier tray configuration. Each carrier tray may approximately rectangular in configuration and each carrier has a plurality of compartments, each compartment approximately rectangular in configuration. 
         [0012]    A method of stacking carrier trays, including: (i) placing a first carrier tray on a surface; (ii) rotating a subsequent carrier tray 180° relative to the first carrier tray; (iii) placing the subsequent carrier tray on top of the first carrier tray; and (iv) repeating the rotating and placing of subsequent carrier trays until a stacked carrier tray configuration is formed is herein disclosed. The method may further include: (i) fitting a plurality of pins of the first carrier tray to a plurality of pin holes of the subsequent carrier tray wherein the first carrier tray is offset relative to the subsequent carrier tray; and (ii) repeating the fitting for each subsequent carrier tray of the stacked carrier tray configuration. The method may further include: (i) forming a gap between a top surface of the first carrier tray and a bottom surface of the subsequent carrier tray; and (ii) repeating the forming for each subsequent carrier tray of the stacked carrier tray configuration. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  illustrates a pallet having a stack of conventional carrier trays. 
           [0014]      FIG. 2  illustrates a perspective view of a carrier tray according to one embodiment of the invention. 
           [0015]      FIG. 3  illustrates a bottom view of the carrier tray of  FIG. 2 . 
           [0016]      FIG. 4  illustrates a fragmentary view of the carrier tray  200  of  FIG. 2 . 
           [0017]      FIG. 5  illustrates a first carrier tray and a second carrier tray being stacked together according to an embodiment of the invention. 
           [0018]      FIG. 6  illustrates the first and second carrier trays of  FIG. 5  stacked on top of each other according to one embodiment of the invention. 
           [0019]      FIG. 7  illustrates a cross-sectional view of the first and second carrier trays of  FIG. 5  taken along first dividers of the first and second carrier trays. 
           [0020]      FIG. 8  illustrates a cross-sectional view of the first and second carrier trays of  FIG. 5  taken along second and third dividers of the first and second carrier trays. 
           [0021]      FIG. 9  illustrates an alternative cross-sectional view of the first and second carrier trays of  FIG. 5  taken along second and third dividers of the first and second carrier trays. 
           [0022]      FIG. 10  illustrates a sectional view of the first and second carrier trays of  FIG. 5  taken along first dividers of the first and second carrier trays. 
           [0023]      FIG. 11  illustrates a pallet having a stack of carrier trays stacked thereon according to an embodiment of the invention. 
           [0024]      FIG. 12  illustrates a pallet having a stack of carrier trays according to an embodiment of the invention next to a stack of conventional carrier trays. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]    The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims. 
         [0026]    In the following description, certain terminology is used to describe certain features of one or more embodiments of the invention. The term “container” refers to any type of device for holding objects, including a receptacle, a bin, a box, a carton, a case, and a crate. The term “food” refers to any type of edible substance including all types of fruits, vegetables and bakery goods. 
         [0027]      FIG. 1  illustrates a pallet having a stack of conventional carrier trays. As shown, it is difficult to determine the contents of the carrier trays. As a result, each conventional carrier tray must be opened individually to determine whether its contents are expired for quality control purposes. This manual task may take an inordinate amount of time and the cost associated therewith may be passed onto the consumer in terms of higher priced contents, i.e., produce. 
         [0028]      FIG. 2  illustrates a perspective view of a carrier tray  200  according to one embodiment of the invention. The carrier tray  200  may be quadrilateral in configuration, i.e., a rectangle, square or similar shape; however, other geometric configurations appropriate for applications of use of the carrier tray  200  are within the scope of the invention. In a preferred embodiment, however, the carrier tray  200  is quadrilateral, i.e., rectangular in shape. The carrier tray  200  may be about four (4) inches in height, about twenty-four (24) inches in length and about fourteen (14) inches in width. This configuration facilitates stacking of multiple carrier trays (explained in more detail below). According to the embodiment shown, the carrier tray  200  includes a first compartment  202 , a second compartment  204 , a third compartment  206  and a fourth compartment  208  for storing, placing and transporting individual containers of food, e.g., produce. Each of the compartments  202 - 208  may have a flat or patterned bottom surface  210 - 216 , respectively, with a plurality of apertures  218  therein. In the embodiment in which the surfaces  210 - 216  are patterned, the pattern may be a series of raised diagonally-oriented striations in parallel to one another or other shapes of flutes, gussets or other patterns. In this respect, when a container is placed therein, the container is raised so that the containers are easy to extract therefrom. Additionally, this configuration allows air to circulate around the bottom of an individual container situated within the carrier tray  200 , i.e., within the first compartment  202 , the second compartment  204 , the third compartment  206  and/or the fourth compartment  208 , which is important in maintaining the freshness of food packed and transported within a container. 
         [0029]    In one embodiment, a first divider  220  extends continuously upwardly from the bottom surfaces  210 - 216  to separate the first and second compartments  202  and  204  from the third and fourth compartments  206  and  208  and also forms inner end walls of the compartments  202 - 208 , respectively. The first divider  220  may include a center notch  222  and at least two end notches  224  for strengthening the carrier tray  200  and for providing ventilation ports when multiple carrier trays are stacked or nested on top of each other (not shown, see  FIG. 6 ). More particularly, the stacked carrier design according to embodiments of the invention allow for air to ventilate completely throughout a “gap” between the perimeter of the bottom of a top carrier tray and a top of a bottom carrier tray. The ventilation ports allow air to flow through to the individual containers when multiple carrier trays are stacked together thereby cooling the contents within the individual containers. Also, the ventilation ports partially or substantially alleviate premature expiration of the contents within carrier produce during packing, storing and transportation. According to some embodiments, the wall comprising first divider  220  may have varied thickness throughout. For example, the outer portions of the first divider  220  may have a first thickness while the inner or middle portion of the first divider  220  may have a second thickness greater than the first thickness. Additionally, a plurality of inner guide pads  226  may be located at appropriate corners adjacent to the first divider  220  for additional reinforcement. These features provide reinforcement in the middle portion when stacking while providing enough flexibility to the outer portions when unloading or unstacking (hereinafter used interchangeably). 
         [0030]    According to one embodiment, a second divider  228  extends continuously upwardly from the flat bottom surfaces  210 - 216  to separate the first compartment  202  from the second compartment  204  and also forms a shared inner sidewall therebetween. Similarly, a third divider  230  extends continuously upwardly from the bottom surfaces  210 - 216  to separate the third compartment  206  from the fourth compartment  208  and also forms a shared inner sidewall therebetween. According to one embodiment, at least a median portion of both second and third dividers  228  and  230  is substantially lower in height relative to first divider  220 . In this respect, individual containers are easier to remove when a particular carrier tray is unloaded. That is, a gap formed between individual containers positioned in, for example, first compartment  202  and second compartment  204 , allows for a user or user-operated machine to more easily grasp the individual containers for unloading thereof. The second and third dividers  228  and  230  may comprise elevated portions  232  at opposite ends thereto, respectively, as well as a plurality of concave grooves  234  for strengthening the carrier tray  200 . In one embodiment, the elevated portions  232  are approximately triangular in shape. Additionally, a plurality of corner stiffening gussets  236  (only one shown in  FIG. 2 ) may be positioned at the corners where the second divider  228  meets the first divider  220  and the third divider  230  meets the first divider  220 , respectively, for additional reinforcement. 
         [0031]    Each of the compartments  202 - 208  have an outer sidewall  238 - 244  (only outer sidewalls  238 ,  242  are shown in  FIG. 2 ; see  FIG. 3 ), respectively, and an outer end wall  246 - 252  (only outer end walls  246 ,  248  are shown in  FIG. 2 ; see  FIG. 3 ), respectively, extending continuously upwardly from the bottom surfaces  210 - 216 , respectively. A flange  254  is integrally connected to and projecting in an outwardly or generally perpendicular fashion (relative to bottom surfaces  210 - 216 ) from the perimeter of the outer sidewalls  238 - 244  and the outer end walls  246 - 252  (only outer end walls  246 ,  248  are shown in  FIG. 2 ; see  FIG. 3 ). The flange  254  may also include a generally downwardly projecting lip  256  which facilitates handling and stacking of multiple carrier trays. A plurality of depressions  258  may be situated about portions of the flange  254  which function to add strength and stiffness to the top of the carrier tray  200 . 
         [0032]    An inner surface of each outer end wall  246 - 252  may include one or more longitudinal concave grooves  260  and one or more radially projecting protrusions  262  which project inwardly relative to carrier tray  200 . One or more stacking pins  264  may be located on top of at least two radially projecting protrusions  262  for insertion into pin holes  266  (not shown, see  FIG. 3 ) of another carrier tray when multiple carrier trays are stacked together. One or more strengthening gussets  270  may be secured to a bottom portion of the longitudinal concave grooves  260  and to the surfaces defining pin holes  266 . The strengthening gussets  270  add strength and security to the carrier tray  200  when multiple carrier trays are stacked together. As shown, each surface defining a pin hole  266  (i.e., adjacent to a longitudinal concave groove  260 ) is offset from a stacking pin  264  located on an adjacent radially projecting protrusion  262 . In this regard, when a multiple carrier trays are stacked together, each carrier tray is offset from one another (explained in more detail below with respect to  FIG. 5 ). 
         [0033]    In one embodiment, at least two peripheral guide pads  268  are located at a corner within adjacent compartments  204  and  208 , respectively, which may be used to facilitate stacking of multiple carrier trays. In one embodiment, reinforcing gussets  274  may be positioned about the flange  254  approximate to areas in which outer ends of first, second and third dividers  220 ,  228  and  230 , respectively, meet the inner peripheral wall of the carrier tray  200  for improved flange strength. 
         [0034]      FIG. 3  illustrates a bottom view of the carrier tray of  FIG. 2 . In one embodiment, the outer bottom surfaces  276 - 282  include a plurality of ventilations apertures  218  for allowing moisture to escape the carrier tray  200  and allow air to flow through. While food, such as fruit, is being packaged and transported, it must remain cold to retain its freshness. The plurality of ventilations apertures  218  allow cool air to flow into the carrier tray  200  and, thus, cool its contents. 
         [0035]    According to embodiments of the invention, the outer bottom surfaces  278 - 282  may have one or more ventilation apertures  218  or may not include any ventilation apertures at all. The plurality of ventilation apertures  218  may be generally circular in shape. However, in alternative embodiments, the apertures may be other shapes, such as ovals, triangles, squares, or other polygons. The plurality of ventilation apertures  218  may be disposed generally symmetrically around the outer bottom surfaces  278 - 282 . In an alternative embodiment, the apertures  218  may be alternatively configured. 
         [0036]    The outer sidewalls  238 - 244  and outer end walls  246 - 252  (see  FIG. 2 ) may be stiffened by one or more strengtheners, such as an array of ribs  284 , that may extend in a generally upwardly direction from the outer bottom surfaces  276 - 282 , to increase the rigidity of the carrier tray  200  and add download strength. The ribs  284  may be formed integrally with the carrier tray  200 . Each of the outer sidewalls  238 - 244  and outer end walls  246 - 252  (see  FIG. 2 ) may have at least one rib, which at least partially traverses an external surface thereof. In one embodiment, the ribs  284  may be generally parallel to one another. 
         [0037]    As noted with respect to  FIG. 2 , the inner bottom surfaces  210 - 216  may be patterned wherein the pattern may be a series of raised diagonally-oriented striations in parallel to one another. These striations, or ribs  286 , may prevent sagging of the carrier tray  200  in storage and/or transmit, particularly in humid environments and may provide additional air circulation for additional cooling. The ribs  286  may be formed integrally with the carrier tray  200 . Also shown in this view are pin holes  266 .  FIG. 4  is a fragmentary view of the carrier tray  200  of  FIG. 2 . The “offset” nature of a pin  264  and an adjacent surface  272  defining a pin hole  266  (not shown) is illustrated more clearly in this view. 
         [0038]    According to various embodiments, the carrier tray  200  including its various components may be constructed of materials such as polyethylene terephthalate (PET), polystyrenes, polypropylenes, or any other suitable material known in the art. In one embodiment, the carrier tray  200  is made of PET or other plastics which makes it completely or substantially impervious to moisture. In a preferred embodiment, the carrier tray  200  may contain recycled PET or other plastic. This feature makes the carrier tray  200  recyclable. In one embodiment, the first, second and third dividers  220 ,  228  and  230 , respectively, are made from PET by thin wall thermoforming methods as known by one of ordinary skill in the art. 
         [0039]      FIG. 5  illustrates a first carrier tray  500   a  and a second carrier tray  500   b  being stacked together according to an embodiment of the invention. Arrows  586  and  588  generally illustrate how two carrier trays are stacked and secured with the stacking pins of the first carrier tray  500   a  inserted into the pin holes of the second carrier tray  500   b.  More particularly, when the second carrier tray  500   b  is positioned over the first carrier tray  500   a  in preparation for stacking, stacking pins  564   a  of carrier tray  500   a  and pins holes  566   b  (not shown, refer to arrows  588 ) of carrier tray  500   b  are positioned relative to one another such that, when stacking multiple carrier trays “into themselves” for storage or for shipping to processors/packers of produce, the second carrier tray  500   b  is slightly offset, or staggered, relative to the first carrier tray  500   a.  When a subsequent carrier tray is to be added to the stack (the stack comprising the second carrier tray  500   b  stacked on first carrier tray  500   a  at this point in the stacking process), the subsequent carrier tray is rotated 180° relative to the previous carrier tray, i.e., the second carrier tray  500   b,  and then nested onto the inner guide pads  526   b  and peripheral guide pads  568   b  of the previous carrier tray i.e., the second carrier tray  500   b,  to prevent collapse of the carrier tray stack. This process is repeated until all the carriers trays have been added to the stack. That is, each subsequent carrier tray is rotated 180° relative to the previous carrier tray on which it lies.  FIG. 6  illustrates the first and second carrier trays  500   a  and  500   b  of  FIG. 5  stacked on top of each other with the stacking pins  564   a  on the first carrier tray  500   a  engaged in the pin holes  566   b  of the second carrier tray  500   b  according to one embodiment of the invention. As shown, at least one reinforcing gusset  574   a  of first carrier tray  500   a  is outwardly adjacent to the outer perimeter of the bottom portion of second carrier tray  500   b.  On the opposite side of first carrier tray  500   a,  another reinforcing gusset  574   a  is inwardly adjacent, and nestled within an opening, to the outer perimeter of the bottom portion of second carrier tray  500   b.  This feature provides additional support for the offset configuration of a plurality of stacked carrier trays. 
         [0040]      FIG. 7  is a cross-sectional view of the first and second carrier trays  500   a  and  500   b  of  FIG. 5  taken along lines  7 - 7 . The staggered configuration of first and second carrier trays  500   a  and  500   b  as shown by the position of flange  554   a  relative to the outer perimeter of the bottom portion of second carrier tray  500   b  is more clearly illustrated in this view.  FIG. 8  is a cross-sectional view of the first and second carrier trays  500   a  and  500   b  of  FIG. 5  taken along lines  8 - 8 . As shown, a gap  590   b  underlying first divider  520   b  of second carrier tray  500   b  illustrates how air is allowed to pass through a configuration of stacked carrier trays. A gap  590   a  underlying first divider  520   a  of first carrier tray  500   a  is also illustrated, as are second and third dividers  528   a  and  530   a  of first carrier tray  500   a  and second and third dividers  528   b  and  530   b  of second carrier tray  500   b.    FIG. 9  is an alternative cross-sectional view of the first and second carrier trays  500   a  and  500   b  of  FIG. 5  taken along lines  9 - 9 .  FIG. 10  is a sectional view of the first and second carrier trays  500   a  and  500   b  of  FIG. 5  taken along lines  10 - 10 . 
         [0041]      FIG. 11  illustrates a pallet  1192  having a stack of carrier trays  1194  stacked thereon according to an embodiment of the invention.  FIG. 12  illustrates a pallet  1292  having a stack of carrier trays  1294  next to a stack of conventional carrier trays  1296 . As shown, the contents of the stack of carriers  1294  are visually readily identifiable, while the contents of the conventional carrier trays  1296  are not necessarily visually readily identifiable. 
         [0042]    One advantage of the invention is that the carrier tray may be made from a transparent material which allows for quick identification of the contents. Conventional corrugated carrier trays do not allow for quick identification. Another advantage of the invention provides for faster product cooling once the carrier tray is loaded due to the aerodynamic design of the way the carrier trays stack together and provide for air flow around the individual containers within the carrier trays. 
         [0043]    While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention is not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art.