Stackable tray having anti-pivot stop and wash apertures

A multi-purpose tray including a front, a back, a first side, a second side, and a bottom. The tray can include beams extending from the front of the tray and slots defined in the back of the tray. When two trays are stacked in opposite directions with respect to one another, the beams are received by the slots. The tray also includes a domed bottom. The domed bottom has a convex profile with respect to the interior of the tray and can include transverse ribs or longitudinal ribs. The tray also includes drain apertures positioned along the front and back of the tray. The drain apertures can enhance cleaning of the tray by communicating fluid from channels defined by the front and back. The tray also includes a stop for projection for limiting sliding movement of a top tray relative to a bottom tray when two trays are stacked in a similar orientation with respect to one another. The tray also includes handles in the first and second side and a gripping portion on one of the first and second handles.

FIELD OF THE INVENTION

This invention generally relates to multi-purpose reusable load-bearing trays and, more specifically, to trays adapted to be nestable or stackable in three positions.

BACKGROUND OF THE INVENTION

Plastic trays that are stackable and/or nestable can be desirable to maintain cargo such as material and/or products. However, existing trays are not as efficient as desired. Specifically, existing trays can require excessive handling time and cleaning time. Also, the existing trays may not nest together as well as desired. An improved tray is needed.

SUMMARY OF THE INVENTION

The present invention provides an improved tray for maintaining cargo during transport. The tray of the present invention can include one or more drain apertures disposed along a front or back of the tray. The drain aperture can improve the efficiency of the tray by improving the cleaning of the tray. In particular, the structure of the existing trays can define blind holes and pockets in which debris and/or vermin can accumulate. Positioning a drain aperture adjacent the blind holes or pockets of the tray can enhance the likelihood that the debris can be quickly removed during cleaning. The drain aperture can be disposed along any surface of the front or back of the tray and can be defined, at least in part, by ribs disposed between a wall and an apron of the front or back of the tray. The ribs can be any shape as desired, including arcuate, straight, cross-shaped, or T-shaped. A drain aperture can also be formed in a notch defined in the front or back of the tray; the notch being used for aligning two trays during stacking.

The present invention also provides a tray with a domed bottom. The bottom of the tray can be convex with respect to the interior of the tray. The domed shape of the bottom of the tray can enhance the strength of the tray. The bottom can also include at least one transverse and/or at least one longitudinal rib to enhance the strength of the bottom. The bottom can be formed with a convex or concave profile.

The present invention also provides a tray with two handles where one of the handles includes a gripping portion. By disposing a gripping portion on only one of the handles, a user of the tray can quickly identify the orientation of the tray. The efficiency of the tray is enhanced when a user can quickly identify the orientation of the tray during stacking the of trays.

The present invention also provides ribs disposed in a pocket of a bottom tray for receiving and engaging feet of a top tray. The ribs can enhance the alignment of two trays stacked relative to each other and support a top tray during sliding movement relative to a bottom tray. A rib closest to the center of the tray can be tapered to reduce the likelihood that a top tray will bind relative to a bottom tray when the two trays are being engaged.

The present invention also provides a stop having a ramp shape positionable in a channel of the tray. When a top tray is engaged with a bottom tray, the top tray is slidingly received by a channel of the bottom tray. The stop disposed in the channel can limit the movement of the top tray relative to the bottom tray when the trays are being engaged with respect to one another. A ramped portion of the stop can enhance the efficiency of the tray by ensuring that sliding movement of the trays will only be prevented in only one direction.

The present invention also provides a tray having beams disposed on a front of the tray and corresponding slots formed in the rear of the tray. The corresponding beams and slots can permit two trays to be stacked on top of one another when in a similar orientation. The support of the top tray relative to the bottom tray, when two trays are stacked in similar orientation, does not occur at the outermost edges of the front corners of the trays. The beams can be received by the slots when two trays are stacked in an opposite direction relative to one another.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Various embodiments of the present invention are shown throughout the figures. These figures include common elements in different structural configurations. Common elements are designated with a common base numeral and differentiated with a alphabetic designation.

Referring now toFIG. 1, the present invention provides a multipurpose tray10. The tray10can include a front12, a rear14, a first side16, a second side18, and a bottom20which can be integrally formed with respect to one another. The tray10can be fabricated from plastic in an injection molding process.FIG. 15shows another embodiment of the invention, a tray10a having a front12a, a rear14a, a first side16a, a second side18a, and a bottom20a which can be integrally formed with respect to one another.

Referring now toFIGS. 1 and 2, the front12can extend from the first side16to the second side18and can include a wall22, a fillet24and an apron26. The wall22, fillet24and apron26can define a channel28. The front12can also include a right-hand portion30and a left-hand portion32which are mirror images of one another with respect to a substantially vertical center axis186of the front12, as best seen inFIG. 10.

Referring now toFIG. 3, the fillet24can define an opening34. The opening34can be centered along the axis186of the front12with respect to the right-hand portion30and the left-hand portion32. The opening34can include a bottom surface36and side surfaces38and40. In a second embodiment of the invention, an opening34a is shown in perspective view inFIG. 15, in partial detailed cross-sectional view inFIG. 16, and in overhead plan view inFIG. 17. The opening34a can be defined by a fillet24a of a front12a of tray10a. The opening34a can include bottom surface36a, side surfaces38a and40a as well as secondary bottom surfaces36b and36c and secondary side surfaces38b and40b.

Referring now toFIG. 5, the fillet24can also define a boss42, a notch44, a gain46, and a dimple48. The boss42is positioned along the length of the front12between the opening34and the notch44. The boss42includes a support surface50. A projection52can extend from the fillet24between the notch44and the gain46. The dimple48can be positioned at an outermost edge of the front12. An alternative embodiment of the dimple48a is shown extending a height of an apron26a of the tray10a inFIGS. 17,18and20.

Referring now toFIGS. 1-5, fillet24can be pierced by one or more apertures54. A plurality of apertures54can be evenly spaced along the length of the front12. The apertures54can be formed in the bottom surface36of the opening34, the side surfaces38and40of the opening34, or in the notch44. The apertures54can enhance cleaning of the tray10by reducing the likelihood that vermin or debris will become trapped in the channel28.

Referring now toFIG. 4, ribs can be disposed in the channel28to define a plurality of apertures and to enhance the structural integrity of the tray10. Referring toFIG. 5, ribs56,58,60and62can be formed in various shapes and be disposed at various positions relative to the opening34. As shown inFIG. 16, ribs64,66,68and70can be positioned adjacent a side surface38a, a secondary bottom surface36b and a bottom surface36a or any combination thereof.

Referring now toFIG. 5, the front12also includes a wall22. The wall22can define a foot72and shoulder74. The foot72can be shaped to correspond to the shape of the notch44. Also, the foot72is substantially vertically aligned with the notch44. The shoulder74will be described in greater detail below.FIG. 18shows a front wall12a of a tray10a having wall22a that defines a foot72a and shoulder74a. The foot72a is shaped to correspond to the shape of the notch44a and is substantially vertically aligned with the notch44a.

Referring again toFIG. 5, a beam76extends from wall22generally toward the apron26. The beam76does not extend past the apron26. The beam76can be tapered such that the beam76is narrowest immediately adjacent the foot72. The beam76is substantially vertically aligned with the support surface50.FIG. 18shows a front12a having a beam76a substantially vertically aligned with the support surface50a of a boss42a.

Referring now to FIGS.1and6-9, the rear14of the tray10can be substantially similar to the front12of the tray10. The rear14can include a wall22b, a fillet24b, and an apron26b. The fillet24b can define an opening34b, including bottom surface36d and side surfaces38c and40c, and a boss42b. One or more apertures54can pierce the fillet24b along the surface36d, or a notch44b. The rear14also includes a slot78. The slot78extends vertically downward from the boss42b along the wall22b. The slot78can be tapered to be narrowest at a position furthest from the boss42b. The slot78is substantially aligned with the beam76of the front12to receive a beam76when two trays10are stacked 180° relative to another. The stacking of two trays relative to one another will be described in greater detail below. The rear14does not include beams extending from the wall22b as best seen inFIG. 9. Also, the rear14may not include a dimple28as formed in the front12.

FIGS. 15 and 19show the rear14a of alternative embodiment of the invention. The rear14a can be substantially similar to the front12a of the tray10a. The rear14a can include a wall22c, a fillet24c, and an apron26c. The fillet24c can define an opening34c, including bottom surfaces36e,36f and36g as well as side surfaces38d,38e and40d,40e and a boss42c. One or more apertures54can pierce the fillet24c along the surfaces36e,36f,36g,38d,38e,40d and40e, or a notch44c. The rear14a also includes a slot78a. The slot78a extends vertically downward from the boss42c along the wall22c. The slot78a can be tapered to be narrowest at a position furthest from the boss42c. The slot78a is substantially aligned with the beam76a of the front12a to receive a beam76a when two trays10a are stacked 180° relative to another. The stacking of two trays relative to one another will be described in greater detail below. The rear14a does not include beams extending from the wall22c as best seen inFIG. 15. Also, the rear14a may not include a dimple28a as formed in the front12a.

Referring now toFIGS. 1,3,5and8, the second side18can include an inner face80, an outer face82, a top portion84and a bottom portion86. The inner face80can be defined by an innermost surface88, a front pocket90and a rear pocket92. The front and rear pockets90and92can be defined by inwardly facing surfaces96and98, front facing surfaces100and102, rear facing surfaces104and106, and upper facing surfaces108and109, respectively. The inwardly facing surfaces, the front facing surfaces, the rear facing surfaces and the upper facing surfaces of each pocket define openings110and112in the front and rear pockets90and92. The pockets90and92are shaped to substantially correspond to the shape of mating feet disposed on the outer face82of the second side18. The feet will be described in greater detail below.

Referring now toFIGS. 6 and 7, one or more ribs114can be disposed on the inwardly facing surface98of the rear pocket92. The ribs114are generally arcuate or semi-circular in cross section. A rib116positioned closest to the center of the second side18can be tapered, such that a radius of the rib116is greater than a radius of the ribs114. The rib116and ribs114can project from the surface98the same distance. Tapering the rib116and enhances the sliding interaction between two trays10to be stacked relative to one another. Specifically, it has been found that when the rib116is shaped without a tapered semi-circular cross section, a top tray sliding relative to a bottom tray can bind.

Referring now toFIGS. 5,9and1, the outer face82of the second side18can include a honeycomb section118, a front foot120and a rear foot122, and an outwardly facing surface124. The honeycomb section118can be disposed adjacent to the top portion84of the second side18. The honeycomb section118enhances the strength and rigidity of the tray10. Opposite of the front pocket90of the inner face80a planar surface126is disposed on the outer face82. Numerical and alphabetic information can be molded or formed on the surface126. Runners128and130extend downwardly toward the bottom portion86from the honeycomb section118.

Referring now toFIGS. 5 and 9, the front foot120and a rear foot122extend from the outwardly facing surface124of the outer face82. The feet120and122include runners132and134respectively. The feet120and122can be honeycombed. The front foot120is shaped to correspond to the shape of the rear pocket92. The rear foot122is shaped to correspond to the shape of the front pocket90. The front foot120can be defined in part by an outer surface or plane136, best seen inFIG. 5. The rear foot122can be defined by two outer surfaces or planes138and140. The surfaces138and140are disposed at an angle of greater than 0° relative to one another.

Referring now toFIGS. 1,5and8, the top portion84of the second side18is defined by a plurality of upper facing surfaces142,144,146,148,150,152,154, and156. Surfaces144and148are downwardly recessed with respect to surface142. Surfaces142,146and150are substantially co-planar. Surfaces152,154and156define the bottom surface of a discontinuous channel158extending along the top portion84of the second side18between the front12and the rear14. The channel158is longitudinally aligned with the gain46of the front12and a gain46a of the rear14. A stop160is disposed in the channel158. The stop160can be shaped like a ramp with a substantially vertical side facing toward the front12and a substantially ramped side facing the rear14. The stop160can prevent movement of a top tray relative to a bottom tray when two trays are to be stacked in a similar orientation and slidingly engaged in a first direction as will be discussed in greater detail below. The first direction is defined when the front of a top tray is engages the rear of the bottom tray at the beginning of the sliding engagement. The second direction is defined when the rear of the top tray is received by front of the bottom tray during the beginning of the sliding engagement. Surface152is downwardly recessed with respect to surface154and a rounded shoulder162can be defined therebetween.

Referring now toFIG. 9, the bottom portion86of the second side18includes two longitudinal rails164and166that extend between opposite edges of the foot72of the front12to a foot72b of the rear14. Transverse rails168can be randomly or evenly spaced between the rails164and166along the length of the second side18.

Referring now toFIGS. 1 and 3, the first side16and the second side18are substantially mirror images of one another with respect to a longitudinal axis190. However, the sides16and18are different in that a configuration of a handle170of the second section18is different than a configuration of a handle172of the first section16. Specifically, one of the handles170and172includes a gripping portion174. The gripping portion includes one or more rounded projections extending into a cavity defined by the handle.FIGS. 1 and 3illustrate a gripping portion174having one rounded projection extending from handle portion172. However, the gripping portion can extend from the handle portion170and can include more than one rounded projection.FIG. 15illustrates a gripping portion174a including a plurality of rounded projections.

Referring toFIGS. 1,3and15, the gripping portions174and174a generally conform to the hand of a user of the tray10or tray10a. The gripping portion174can be advantageous to indicate to a human handler the orientation of the tray. For example, if the trays are to be stacked at 180° relative to one another, the human handler can grasp a tray to be stacked and recognize whether the tray can be placed on top of a stack of trays or must be oriented differently before the tray is stacked by feeling the gripping portion instead of having to examine the sides of the tray to identify the location of the beam76of the tray being held and the slot78of the tray at the top of the stack of trays. Specifically, when trays are to be stacked at 180° relative to one another, the human handler will recognize that every other tray must be grasped so that the gripping portion is felt with a particular hand. When the trays are to be stacked at 0° relative to one another, the human handler will recognize that every tray must be grasped so that the gripping portion is felt with a particular hand.

Referring now toFIGS. 15,17and22, the first side16a and second side18a of the tray10a according to an alternative embodiment of the invention can be substantially similar to the first side16and second side18of the tray10, respectively. The first side16a and second side18a can be mirror images of one another about a longitudinal axis198. Each side can include an inner face80a, an outer face82a, a top portion84a and a bottom portion86a. The inner face80a can be defined by an innermost surface88a, a front pocket90a and a rear pocket92a. The front and rear pockets90a and92a can be defined by inwardly facing surfaces96a and98a, front facing surfaces100a and102a, and rear facing surfaces104a and106a, respectively. The rear pocket92a can include an upper facing surface109a. The inwardly facing surfaces, the front facing surfaces, the rear facing surfaces and the upper facing surfaces of each pocket define openings110a and112a in the front and rear pockets90a and92a. The pockets90a and92a are shaped to substantially correspond to the shape of mating feet disposed on the outer face82a. The feet will be described in greater detail below.

Referring now toFIG. 22, the outer face82a can include a honeycomb section118a, a front foot120a and a rear foot122a, and an outwardly facing surface124a. The honeycomb section118a can be disposed adjacent to the top portion84a of the second side18a. The honeycomb section118a enhances the strength and rigidity of the tray10a. Opposite of the front pocket90a of the inner face80a a planar surface126a is disposed on the outer face82a. Numerical and alphabetic information can be molded or formed on the surface126a. Runners128a and130a extend downwardly toward the bottom portion86a from the honeycomb section118a.

Referring now toFIGS. 15 and 24, the front foot120a and a rear foot122a extend from the outwardly facing surface124a of the outer face82a. The feet120a and122a include runners132a and134a respectively. The feet120a and122a can include ribs200. The front foot120a is shaped to correspond to the shape of the rear pocket92a. The rear foot122a is shaped to correspond to the shape of the front pocket90a. The front foot120a can be defined in part by an outer surface or plane136a. The rear foot122a can be defined by two outer surfaces or planes138a and140a. The surfaces138a and140a are disposed at an angle of greater than 0° relative to one another.

Referring now toFIG. 17, the top portion84a is defined by a plurality of upper facing surfaces142a,144a,146a,148a,150a,152a,154a, and156a. Surfaces144a and148a are downwardly recessed with respect to surface142a. Surfaces142a,146a and150a are substantially co-planar. Surfaces152a,154a and156a define the bottom surface of a discontinuous channel158a extending along the top portion84a between the front12a and the rear14a. The channel158a is longitudinally aligned with the gain46b of the front12a and a gain46c of the rear14a. Surface152a is downwardly recessed with respect to surface154a and a shoulder162a can be defined therebetween.

Referring now toFIGS. 15,20and21, the bottom portion86a of each side of the tray10a can be substantially similar to the bottom portion of each side of the tray10. Specifically, each bottom portion of the first and second sides16a and18a can include two longitudinal rails that extend between opposite edges of the foot72a of the front12a to a foot72c of the rear14a. Transverse rails can be randomly or evenly spaced between the longitudinal rails along the length of the first and second sides16a and18a.

Referring now toFIGS. 1,3,8and25, a bottom20of the tray10can define a lattice pattern. The bottom20can also include longitudinal ribs176and transverse ribs178. The bottom20can also be domed to increase the strength of the tray10and reduce the material required to form the bottom20. The bottom20a of tray10a can be domed. The shape of a domed bottom surface is shown schematically inFIG. 25. The front and sides of the tray are shown in phantom and a line180illustrates a profile of the bottom20along the transverse direction. Line182illustrates that the bottom can also be arched along the longitudinal direction. Line188illustrates a profile of a bottom that is not domed. The dome configuration of a bottom can increase the strength of the bottom by fifty percent. Tray10a can include a domed bottom20a. The enhanced strength of a domed-shaped bottom20can also reduce the amount of material necessary to form the bottom20when a predetermined strength is required.

Preferably, the dome is three-eights (⅜) of one inch at the center of the bottom20. In other words, the center of the dome extends toward the interior of the tray10three-eights (⅜) of one inch relative to the intersection of the bottom with the sides16and18, and the front12and rear14. However, the height of the dome can be increased or decreased as desired. The height of the dome can be varied based on the weight of the material and/or products to be maintained in the tray10. In particular, the dome can be completely or partially flattened relative to the intersection of the bottom20and with the sides16and18, and the front12and rear14in response to a weight of the cargo to be maintained by the tray10. The height of the dome can be determined based on the projected flattening of the dome in response to weight of the cargo to be maintained by the tray10.

Two or more trays can be stacked on top of one another in three different configurations. The height of two stacked trays in each configuration can be different. The trays can be blind stacked and unstacked. The engagement of two trays10and two trays10a is substantially similar.

In a first configuration, a bottom tray10and a top tray10are stacked in the same orientation, or at an angle of 0° relative to one another. In the first configuration, the second side18of the top tray engages the second side of the bottom tray.FIG. 10is a front plan view of two trays stacked in the same orientation andFIG. 13is a side plan view of two trays stacked in the same orientation. When two trays are stacked in a similar orientation, a foot72a of a rear14of an upper tray is received by the notch44of the front12of a lower tray. The trays are moved relative to one another and a runner134of the upper tray enters the gain46of the front12of the lower tray and slides along the channel158. An edge184of the rear foot122slidingly contacts surface142of the second side18of the lower tray. The runner134of the rear foot122engages the tapered rib116and moves past the rib116and ribs114. The runner132of the top tray enters the gain46of the lower tray. The sliding motion of the top tray relative to the bottom tray stops when the runner134contacts or abuts the stop160of the lower tray. As shown inFIG. 10, when the upper tray is stacked relative to the lower tray in the same orientation, a beam76of the top tray contacts the support surface50of the boss42of the lower tray, the runner132of the upper tray engages the surface152of the lower tray, the runner134of the upper tray engages the surface156of the lower tray, and the edge184of the upper tray engages the surface142of the lower tray and the ribs114and116. Substantially the same engagement occurs between the first side16of the top tray and the first side16of the lower tray.

In a second configuration, a bottom tray and a top tray are stacked in the opposite orientation, or at an angle of 180° relative to one another. In the second configuration, the first side18of the top tray engages the second side of the bottom tray.FIG. 12is a front plan view of two trays stacked in thesameoppositeorientation andFIG. 14is a side plan view of two trays stacked in thesameoppositeorientation. A foot72of the front12of the top tray enters the notch44of a lower tray. A runner132enters the gain46of the lower tray and slidingly contacts the surfaces152and154of the channel158. A runner134enters the gain46. When the front and rear feet120and122of the top tray are aligned with the rear and front pockets92and90, respectively, of the bottom tray, the top tray drops into engagement with the bottom tray. The ribs114engage surface136to reduce the likelihood that the top tray will move relative to the bottom tray. When the top and bottom tray are engaged at an angle of 180° relative to one another, a beam76of the top tray is slidingly received in the channel78(shown in phantom inFIG. 12), runners128and130of the top tray contact surface154of the bottom tray, runner132of the top tray pierces the opening112of the bottom tray, runner134pierces the opening110of the bottom tray, and the bottom of the apron26of the top tray engages the top of the apron26b of the rear14of the bottom tray. Substantially the same engagement occurs between the second side18of the top tray and the first side16of the lower tray.

In a third configuration, a bottom tray and a top tray are stacked at an angle of 90° relative to one another. In the third configuration, the bottom20of the top tray engages the bottom surfaces36and36d of the bottom tray.FIG. 11is a rear plan view of two trays stacked at an angle of 90° relative to one another. The trays can be stacked so that a bottom edge of a wall22of a top tray engages the fillet24of the front12of a bottom tray and a fillet24b of the rear14of the bottom tray. The shoulder74and a shoulder74a of the front12of the top tray engage the aprons26and26b and limit the movement of top tray relative to the bottom tray. Like shoulders can be formed in the rear14to engage the aprons26and26b.