Bakery tray with blind stacking and unstacking

Abstract: A unitary molded plastic bakery tray, with the end walls (3, 4) higher than the side walls (5, 6) to provide for a 90 degree cross-­ nesting, and the end walls (3, 4) having interengaging feet and rails to provide for 180 degree oriented high stacking and like oriented low stacking. The bottom (2) is either a flat planar surface with chamfered bottom edges (12) or is raised so that the tray is provided with corner structure having chamfered bottom edges. Blind stacking structure is provided by an additional outer rail (31) on each end wall and additional outer feet on each end wall for engaging the outer rail. Alternatively, blind stacking is provided by structure along each end wall having large feet (21) and cooperating large recesses (20) coplanar with inner small feet (22) and cooperating inner recesses (19) such that the large feet can span and smoothly slide over the small recesses (19) during blind stacking. Further, trays of different series having different stacking heights can be blind stacked on one another during stacking, but include bottom and side wall structure that prevents inter cross-­ nesting of trays of different series.

Description: The present invention relates to bakery trays that are generally rectangular with high end walls, lower side walls, and a bottom so that they may be cross-nested at a 90 degree orientation, the trays being further provided with interengaging feet and rails so that they may be stacked at high and low positions with 180 degree orientation and like orientation, said 90 and 180 degree orientation always being, here and in the following description, with reference to a vertical axis, perpendicular to the bottom of the trays. These trays are moved about singularly and in stacks by sliding across floors and other surfaces, and by movement along conveyors, such as roller or wheeled conveyors. The trays are also manually handled, for example by being stacked in various orientations in large stacks at different locations, including within a truck. Such stacks sometimes reach a height greater than the height of the person doing the stacking. Further stacking must then be done overhead and is termed blind stacking. "Blind stacking" containers thus involves stacking of containers without visual surveillance. During blind stacking, it is very common to have various portions of the trays hang up by interfering engagement to provide excess forces or to stop the sliding. Such stopping or excess forces can become quite annoying to the operators, produce forces that would topple a stack of trays, and generally increase handling time. These trays are used in great volume by large bakeries, distributors and retailers, so that small differences tend to take on large proportions when multiplied by the volume of trays in use. For example, a small annoyance or small delay in blind stacking becomes very large when repeated thousands of times, where there are tens or hundreds of thousands of trays within one distribution system. Bakery trays can be provided with feet that ride upon rails, so that a top tray of a large stack may be inserted by placing its far bottom portion on the top rails of the adjacent front portion of the current tray at the top position and then sliding the top tray until it is in alignment, at which time feet of the top tray will become vertically aligned with recesses of the adjacent lower tray so that the two will interengage at some stacking position or interengage at a lower nesting position. There are many other bakery trays that will stack and nest and many other types of molded plastic containers as well as stacking and nesting containers in general, to which the present invention relates. Containers may interengage for purposes of nesting at a low level, stacking at a high level, or stacking at an intermediate level, and in such situations feet usually engage in some type of recess. United States Patent Specification 4 402 408 discloses a container in the form of a tray having ends walls of differing construction such that when two of the containers are stacked one upon the other with like end walls one upon the other, components of the end walls cooperate to give a determined stacking height and when the two containers are stacked with unlike end walls one upon another, components of the end walls cooperate to give a different stacking height, rails being provided along the end walls to allow sliding stacking. According to the invention there is provided a unitary molded plastic bakery tray having a rectangular bottom, a pair of opposed side walls a pair of opposed end walls the side walls and the end walls being alternately connected to each other and to the bottom around the perimeter of the bottom to provide an upwardly opening rectangular tray, interengaging means along the end walls to provide first and second different vertical stacking positions of like trays in a like orientation and a 180 degree rotated orientation, respectively, to hold therebetween bakery products of corresponding height during storage and transportation, and stacking rail means along the upper edge of each of the end walls being spaced outwardly from and separate from the interengaging means, characterised by guide feet at the opposite ends of each of the end walls adjacent the bottom, and outwardly spaced from and separate from the interengaging means, and recesses at opposite ends of each of the stacking rail means vertically aligned with the guide feet respectively freely to receive therein the guide feet to a nesting depth of like containers sufficiently for the interengaging means to provide each of the first and second stacking positions, and wherein each of the guide feet has a flat bottom portion and the stacking rail means is an upper flat edge of each of the end walls constructed to receive and support thereon the flat bottom portions of the guide feet to maintain like orientation or 180 degree orientation of like containers vertically spaced at a height greater than the first and second positions so that, when blind stacking (as hereinbefore defined) containers, the guide feet engage the stacking rail means slidably along the entire length of the stacking rail means to maintain the interengaging means spaced from each other and inoperative until the guide feet align with and interengage with the guide recesses. The end walls and side walls provide for 90 degree cross-nesting. The end walls of a first series of trays have interengaging feet and rails to provide for 180 degree oriented high stacking and like oriented low stacking. Another series of trays has interengaging feet and rails for either 180 degree oriented or like oriented stacking that is of the same height. The trays of the first and second series are interstackable. Accordingly, high and low stacking of one series of trays allows for the transporting of goods of two different product heights while interstacking of the first series of trays with another series of trays allows the transporting of additional goods of different product height. Blind stacking of the trays of either series is provided by an additional outer rail at the upper end of each end wall of the tray and laterally extending outer feet at the bottom of each end wall to engage the outer rail. Further, in one series of trays, the plurality of feet can be divided between outwardly spaced large feet and inwardly spaced small feet and cooperating outer and inner recesses that are sized to receive the large and small feet. The large and small recesses are aligned with the large and small feet in like orientation to provide low stacking of the series of trays. In 180 degree orientation, the feet and recesses are out of alignment so that the feet of an upper tray are stacked onto the channel of a lower tray to provide high stacking. After transporting of the goods with the trays, cross-nesting is permitted by changing the orientation between upper and lower like series of trays by 90 degrees. Further, side wall-bottom wall interengaging structure is provided that prevents cross-nesting between trays of different series, even though trays of different series may be interstacked with one another by providing the appropriate end wall foot and recess structure. Generally flat planar bottom surfaces of the trays can include chamfered or bevelled edges. The trays may have a stacking corner structure at the bottom of the trays and corresponding raised bottom wall construction that spaces the bottom wall of the trays off of the planar surface on which they are supported and provides rigidity at the corners of the tray to allow for stacking the trays in large numbers. To unstack this type of container, it is the usual practice to vertically pick up the upper container as a whole, to disengage the feet from the recesses, after which time the container may be further removed in an upward vertical direction, removed in a horizontal direction with a sliding motion, or removed at some angle therebetween, generally in a plane parallel with the side walls when the user is facing an end wall, although terms such as end wall and side wall are many times interchangeable. Of course, the upper container or containers may be removed in other planes and at other angles, but the above type of removal is usual. While unstacking is awkward in general, and the present invention improves such unstacking, the present invention has particular advantage with respect to a problem wherein one or a plurality of trays has been blind stacked. Blind stacking refers to the situation wherein a user has lifted up one or a plurality of trays, particularly above his head, and rested the bottom portion of the bottom most tray at the far end, with respect to the user, upon the adjacent top of the top most tray of a high stack, and thereafter pushed a tray or trays that he is holding along the top tray of the stack until all the trays become properly aligned, which is usually completely vertically aligned, at which time there may or may not be some interengagement between the trays to prevent their further horizontal relative movement and/or to permit the nesting of the trays to save space when they are empty, or the intermediate level stacking of the trays when there are small products within the trays. Blind stacking is advantageous because it is usually difficult or impossible to support the top tray or trays completely until they are vertically aligned with the top tray of the stack, because of the height of the stack or the side constraints of other stacks or a truck. There is a particular problem in trying to unstack the top or a plurality of top trays from such a stack, because again it is difficult or impossible to bodily lift the entire top tray or group of top trays vertically upward until such time that they are disengaged from the adjacent top tray of the remaining stack. The present invention overcomes such a problem for trays or containers in general wherein this problem exists. Particularly, the top tray or plurality of top trays to be removed from such a stack are grasped at their near end by the user and lifted upwardly to disengage the feet and recesses at the near end, while the feet and recesses at the far end remain substantially completely engaged as the tray is tilted upwardly at an angle. At least the feet and recesses remaining engaged have lost motion in the horizontal direction sufficient to shift the lifted trays horizontally without disengaging the feet and recesses at the far end. In addition to the usual type of interengaging structure, the present invention provides a projection, preferably outwardly, from the midportion of each side of the trays that interengages with a generally vertically extending recess of the adjacent lower tray, which projection and recess become disengaged during the above mentioned angular lifting of the top tray or top trays. With the shifting horizontally of the angularly related trays, the projection will now be misaligned with its recess, because the projection and recess do not have lost motion to the extent provided by the end feet and recesses. At this time, the user can merely lower the near end of the tray or trays to be removed so that they will assume a horizontal position as the top tray or trays to be removed pivot about an axis formed by the projection engaging a top surface, outside of the projection recess, of the top tray of the remaining stack. This is an advantageous way to unstack. Recesses refer to any type of opening that can accommodate, in a generally telescopic manner, the feet or projections. The feet or projections may have the identical structure of each other, and are preferably cantilevered outwardly. The recesses may be blind recesses or through slots. An additional advantage of the present invention resides in the provision of additional top structure wherein the projection may ride along such top structure, preferably a rail, so that the projection can support the entire weight of the tray or trays to be removed as such tray or trays to be removed are slide horizontally towards the user by the user merely pulling on the adjacent end, until the trays have moved sufficiently for the user to obtain a better grip on the trays so that they may thereafter be lifted up and removed vertically. When incorporated with the above identified application, the present invention is particularly advantageous in permitting such horizontal sliding movement of almost one-half the corresponding horizontal dimension of the trays, although a sliding motion of one-fourth or one-eighth, for example, of the length of the trays is still advantageous in providing the portion of the trays that can then be gripped by the user so that the trays may be easily lifted up vertically for unstacking and removal. The invention will become more clear from the following detailed description of the preferred embodiments shown in the drawings, wherein: Figure 1 is an elevational end wall view of a tray constructed according to a first embodiment of the present invention; Figure 2 is an elevational view of the opposite end wall of the tray according to Figure 1; Figure 3 is a partial top view, the center portion having been removed to avoid duplication, of the bottom one-half of a tray constructed according to a second embodiment of the invention, with the other one-half of each tray being a mirror image; Figure 4 is an elevational view, in cross-section, of one side of the tray according to the first embodiment, with the other side being identical; Figure 5 is an elevational view of the end wall of a tray constructed according to the second embodiment employed alternatively with the different height trays of Figures 1-2; Figure 6 is an elevational view of the opposite end wall of the tray according to Figure 5, with the elevational side views of this tray being substantially the same, but of reduced size as that shown in Figure 4 for the side walls; Figure 7 is an elevational view of the ends of two like trays constructed according to the first embodiment stacked in a 180 degree oriented high position; Figure 8 is an elevational view of the other ends of the stacked trays according to Figure 7; Figure 9 is an elevational view of the ends of two like oriented trays stacked in a low or intermediate position; Figure 10 is an elevational view of the opposite end of the stacked trays according to Figure 9; Figure 11 is a partial cross-sectional view, in side elevation, of the trays stacked according to Figures 7 and 8, as taken along line XI-XI in Figure 7; Figure 12 is a partial cross-sectional view, in side elevation, of the trays being blind stacked according to Figures 9 and 10, as taken along line XII-XII in Figure 9; Figure 13 is a cross-sectional view, with the center portion broken away, taken along line XIII-XIII in Figure 16, blind stacking being shown; Figure 14 is an elevational view of the side of a lower tray cross-nested with an upper tray in aligned position, with portions broken away; Figure 15 is a partial view, taken in elevation from the side of the lower tray of two cross stacked trays in misaligned position; Figure 16 is an elevational view of the ends of two 180 degree oriented trays constructed according to a modification of the first embodiment sliding along each other during blind stacking; Figure 17 is the opposite end elevational view of the blind stacking of trays shown in Figure 16; Figure 18 is an end elevational view of like oriented trays constructed according to the modified embodiment of Figure 16 being blind stacked; Figure 19 is an elevational view of the other end of blind stacking of trays shown in Figure 18; Figure 20 is one end elevational view of a tray, according to the present invention, showing a third embodiment; Figure 21 is the opposite end elevational view of the tray according to Figure 20; Figure 22 is a side elevational view, taken in cross section along line XXII-XXII of Figure 23, of the tray according to Figure 20, with the cross-sectional view along the same cross-section line taken in the opposite direction being a mirror image; Figure 23 is a top plan view, of one-half of the tray as shown in Figure 20, with the other half being a mirror image; and Figure 24 is a partial cross-sectional view taken along line XXIV-XXIV in Figure 23. figure 25 is a partial elevational view, in cross-section, of one side of the tray constructed according to the second embodiment of the invention, with the other side being identical; Figure 26 is an elevational end wall view of half of a tray constructed according to a fourth embodiment of the present invention, the other half end wall being a mirror image; Figure 27 is a corresponding partial section view; Figure 28 is an elevational view of the opposite end wall of the tray according to Figure 26; Figure 29 is a partial cross-sectional view similar to the sectional view shown in Figure 27, but of the opposite end wall shown in Figure 28; Figure 30 is an elevational view of one half of one side of the tray according to the fourth embodiment, with the other half being a mirror image thereof and the other side being identical; Figure 31 is an elevational view of the ends of two like trays constructed according to the fourth embodiment in a stacked position; Figure 32 is an end elevational view of the trays shown in Figure 31 with the upper trays shown raised at one end; Figure 33 is an end elevational view of the two strays of Figure 32 showing the upper tray raised up at one end and shifted toward the raised end with respect to the lower tray; Figure 34 is a corresponding partial section view; Figure 35 is an elevational view of the trays of Figure 33 showing the upper tray in an unstacked position with respect to the lower tray; Figure 36 shows the trays shown in Figure 34 wherein the upper tray is in a further unstacked position with respect to the lower tray; Figure 37 is a perspective view of trays constructed according to a fifth embodiment of the invention having the blind unstacking feature; and Figure 38 is another perspective view of the trays constructed according to the fifth embodiment of the present invention. Two different height trays of two embodiments of the invention may be stacked with themselves or interstacked, with the larger size tray of a first embodiment being shown in Figures 1, 2, 4 and 7-15, and the smaller size tray of a second embodiment being shown in Figures 3, 5, 6 and 25. A third embodiment of the present invention is shown in Figures 20-24. A fourth embodiment of the invention is shown in Figures 26-36 and a fifth embodiment shown in Figures 37 and 38. With respect to all the embodiments, like numerals have been provided for like parts wherein the descriptions herein are identical, with primes and additional numerals being added to show different tray constructions otherwise. The unitary molded plastic tray of the present invention is used, for example, for storing and transporting bakery goods and the like. It is common for bakery trays to be nestable and stackable in different levels, for conserving space in transporting and storing bakery goods of different height. The bakery tray of the first embodiment is shown in Figures 1, 2 and 4. The tray includes a generally rectangular bottom 2, a pair of opposed end walls 3, 4 and a pair of opposed side walls 5, 6. The walls are serially connected together at corners 7 around the perimeter of the bottom to produce an upwardly opening rectangular container or tray. As seen in Figure 4, the end walls 3, 4 are higher than the side walls 5, 6, so that the trays may be stacked with adjacent like trays rotated in a 90 degree orientation with respect to each other, in a cross-nested relationship as shown in Figures 14 and 15. This type of structure is well known in the art. The bottom structure is in the form of a grid, preferably a rectangular grid, of ribs 8 forming between them a plurality of at least similar small through passages 9 for aerating the bakery goods in trays and for providing lightness of the trays. As shown in the typical cross-sectional view of Figure 4, the side walls 5, 6, the end walls 3, 4 and the ribs 8 all extend downwardly to terminal edges 10 that are coplanar to form a generally parallel horizontal bottom surface 11 interrupted substantially only by the through passages 9 and presenting the lowermost structure of the tray. This bottom planar structure of the terminal edges provides a tray support for providing abrasion resistance when sliding the tray and upper stacked trays that produce considerable weight on the lower tray along an abrading support surface. The abrading support surface could be a surface such as a concrete floor, which is rough and generally wears down plastic trays, particularly when the plastic trays of the prior art have a small support surface that is quickly worn down. With the tray of Figures 1-4, all of the terminal edges 10 of the bottom surface 11 will be contacting the support surface, such as a floor. When the support surface is discontinuous, for example with a roller bed or a floor having a crack, conventional trays have hung up on such a discontinuous surface because of their discontinuous bottom, which might result in jamming of automatic conveying equipment or breaking off of edges, for example when a large stack of trays is pushed across a floor having a crack. According to several embodiments of the present invention, the tray is provided with the substantially planar support surface 11 that will not have such problems when encountering abrading and discontinuous support surfaces as are commonly provided during normal handling of such trays. This function of the tray support bottom surface is provided in all horizontal directions of relative movement between the tray and the support surface such as a conveyor or floor. Chamfers 12 are provided along the entire edge perimeter of the bottom 2, so that the forks of a fork lift truck or the like moving along a support surface such as a floor may engage the bottommost tray of a stack of trays, more specifically engage the fork with the chamfer, to lift the bottommost tray upwardly and over the forks so that thereafter the forks may engage the generally planar horizontal bottom surface 11 of the bottommost tray that otherwise would be engaged in the support surface. In this manner, the chamfer 12 provides a ramp extending upwardly and outwardly from at least the terminal edge of the walls 3, 4, 5, 6 and more specifically around the entire perimeter of the bottom. In addition, these chamfers 12 will assist in moving the trays, particularly with automatic conveying equipment, across a discontinuous surface, such as a roller or wheel conveyor. Further, these chamfers 12 will assist when moving the trays across a discontinuous surface, such as a floor having an upraised crack portion that will engage the chamfer surface 12, without any abrupt stoppage that in the past has broken conventional trays. Also, the chamfer surface 12 is important in preventing engagement with upraised cracks or the like in the floor that might stop the lowermost tray and cause the upper trays of a large stack to continue going forward to thereby upset the entire stack, which can produce considerable problems with respect to ruining bakery products and further breaking additional trays, in addition to providing increased labor time. In the known manner of such trays, the walls are provided with outwardly extending reinforcing ribs 13, for example as seen in Figure 2, which define a handle area 14, and open areas 15. To enable a person handling the trays by the handles to recognize like and 180 degree orientation by feel rather than by sight, handles 14 at one end wall 4 are provided with finger indentations 14a. Returning to the cross-nesting feature as shown in Figures 14 and 15, it is seen that the interior distance between end walls and more particularly between points A, is substantially greater than the exterior distance between the side walls 5 and 6 so that the trays may be cross-nested, with 90 degree orientation between adjacent trays. This is accomplished by having the alternate trays of the vertical stack rotated about a vertical axis 90 degrees with respect to each other. According to the first embodiment, the side walls 5 and 6 have a substantially linear continuous central topmost edge 16 corresponding in length to the side to side width of the bottom surface 11 as measured parallel to the end walls 3, 4, for smoothly and continuously engaging the bottom of an upper tray with the near topmost edge 16 during cross-nesting and thereby providing relative free sliding between the trays. In other embodiments, the side walls have product retention fingers, for example as shown in Figure 25, that extend through the grid of the bottom of an adjacent upper tray during cross-nesting, to be explained in further detail hereinafter with respect to the second and third embodiments of the invention. Each of the side walls 5, 6 is provided with a buttress portion 17 extending from opposite ends of the topmost edge 16 upwardly and outwardly toward the higher end walls 3, 4, respectively. The buttresses portions 17 are at a spacing and orientation for engaging the ramps or chamfers 12 of an upper cross-nested tray, during nesting, as shown in Figures 14 and 15, to guide the trays relative to each other in the horizontal direction parallel to the side walls 5, 6 of the lower tray to an aligned position shown in Figure 14 from a misaligned position shown in Figure 15. This engagement between the buttress portions 17 and the chamfers 12 facilitates aligned cross nesting and initially provides for offcenter room for quick cross-nesting and automatic alignment thereafter. This feature greatly facilitates automated handling, such as with automated assembly lines for cross-nesting the trays without the intervention of humans. Such misalignment and automatic alignment by the surfaces 12, 17, which are at complementary angles, provides considerable tolerances and is necessary for reliable machine cross-nesting in automated equipment. It is to be understood that all of the above described cross-nesting structure could also be provided in the lower height end wall trays shown in Figures 3, 5, 6 and 25. However, the sidewall structure and cross-nesting of these trays is different, as shown, for purposes of illustrating another feature of an embodiment of the present invention. For the trays shown in Figures 1, 2 and 4, there is interengaging structure to provide for like oriented stacking of like trays at a low level or at an intermediate level if the cross-nesting is considered to be a low level. This like orientation is shown in Figures 10 and 12. Like trays may also be stacked in 180 degree orientation, that is rotated about a vertical axis 180 degrees with respect to adjacent trays stacked to produce high level stacking as shown in Figures 7, 8 and 11. The high level stacking, as is known, provides for the storage and transportation of high bakery products such as bread, the low or intermediate stacking provides for intermediate height products such as buns, and cross nesting facilitates the transporting of empty trays or storage and transportation of very low level products. The interengaging structure of the trays of the first embodiment comprises an inside rail 18 and an outer stacking rail 31 along on the upper portion of each of the end walls 3, 4. The rails 18 and 31 form a channel having a channel bottom 28. The inside rail 18 functions as a guide rail along each of the end walls 3, 4. The rail 18 is provided with a pattern of at least two small recesses 19 and at least two large recesses 20 extending downwardly. The pattern of recesses in one of the rails 18, on the end wall 3 is different from the pattern of recesses in the other of the rails 18, on the end wall 4, so that with 180 degree oriented stacked trays, as shown in Figures 7 and 8, vertically adjacent small recesses 19 of adjacent trays will be misaligned vertically for each end wall of adjacent trays and vertically adjacent large recesses of adjacent trays will be misaligned vertically. The interengaging structure further includes a pattern of at least two large feet 21 and at least two small feet 22 along the bottom of each of the end walls 3, 4. The pattern of feet 21, 22 on one end wall 3 is different from the pattern of feet 21, 22 on the other end wall 4. This difference in foot pattern is such that with 180 degree oriented like stacked trays, vertically adjacent large feet will be vertically misaligned and vertically adjacent small feet will be vertically misaligned with at least some of the feet engaging the channel bottom 28 to provide the high position. In the like oriented position of two stacked like trays shown in Figures 8 and 10, the large feet of the upper tray will be received within the large recesses of the lower tray and the small feet of the upper tray will be received within the small recesses of the lower tray to provide a low stacked position. In the positions shown in Figures 7, 8, 9 and 10, it is seen that for each end wall 3, 4, all of the large and small feet are coplanar with each other and coplanar with all of the large and small recesses. The blind stacking of the trays according to the present invention is achieved by a blind stacking structure according to different embodiments of the invention. The preferred blind stacking structure includes the large feet and additional outer guide feet structure, wherein the guide feet engage the stacking rail to guide an upper tray across the end walls of a lower tray. The outboard blind stacking structure will now be described generally, with reference to the first embodiment specifically. Guide feet 30 are provided at opposite ends of each of the end walls 3, 4, adjacent the bottom. As seen, for example in Figure 12, the guide feet 30 are outwardly spaced from and separate from the interengaging structure. The stacking rails 31 have recesses 32 at the opposite ends of the end walls 3, 4, which recesses 32 are vertically aligned with the guide feet 30 and correspondingly shaped to receive the guide feet 30 of a similarly constructed or like constructed tray. The reception of the guide feet 30 within the guide recesses 32 is to a nesting depth of like containers sufficiently for the above-described interengaging structure to provide each of the high and intermediate or alternately stated high and low positions of 180 degree orientation and like orientation of adjacent stacked like containers. The stacking rails 31 between the guide recesses 32 are linear, horizontal, of continuous height and constructed to receive and support thereon the guide feet 30, as shown in Figure 11, of an upper container during blind stacking at the far side and even the near side. Engagement of the guide feet 30 with the stacking rail 31 maintains like oriented and 180 degree oriented like containers vertically spaced at a height greater than the above-mentioned high level stacking and thereby greater than the above-mentioned low and intermediate stacking height. Therefore, with blind stacking of like containers, the guide feet 30 engage the guide rail 31 slidably along the entire length of the guide rail 31 to maintain the interengaging structure spaced from each other and maintain the interengaging structure inoperative until the guide feet 30 align with and interengage or nest with the guide recesses 32, at which time, the interengaging structure can provide the high and low stacking. All of the blind stacking features described above are equally attainable with the low level trays of Figures 3, 5, 6 and 25, wherein like structure is provided with like numerals. Of course, since the high level is not provided with the low trays of this second embodiment, the inner guide rail 18' is not provided with recesses, thus eliminating intermediate and high level stacking. The above-mentioned blind stacking features have related to the forwardmost edge of the top container. There are also blind stacking features relating to the rearwardmost portion of the lower container that engages the bottom of the upper container. With specific reference to Figure 11, the buttress portions 17 are connected to high wall portions 24 of the side walls that have top planar surfaces 25 for engaging the planar bottom surface 11 of a like top tray at the near end, with respect to an operator conducting blind stacking, of like oriented and 180 degree oriented trays. Engagement between the top edge 25 and the bottom surface 11 of adjacent trays during blind stacking at the near portion to the operator occurs linearly and smoothly without interruption throughout the entire blind stacking process coincident with the blind stacking process described above. That is, the surface 25 provides linear sliding engagement continuously during blind stacking to support the near portions of like containers while the far portions of like containers are supported with respect to each other by the guide feet traveling upon the stacking rail 31. According to another feature of the blind stacking of the trays constructed according to the present invention, the large feet 21 extend downwardly into the channel formed between the rails 18 and 31. This feature is in all of the embodiments, but is best shown with respect to the embodiment shown in Figures 13, and 16-19 wherein the feet 21 extend to the bottom of the tray such that the second embodiment of the tray disclosed by these figures is modified from the first embodiment. As shown in Figure 12, the bottom 23 of the large feet 21 extend into the channel but do not touch the bottom surface 28 of the channel so that increased sliding resistance during blind stacking is prevented. It is preferred that the large feet extend into the channel to resist lateral movement of an upper tray being blind stacked onto a lower tray by confining the movement of the bottom portion of the foot within each of the rails 18 and 31. To further aid in blind stacking the trays of each of the embodiments constructed according to the invention, the small recesses have a tapered wall portion 26 that guides the leading edge of an upper tray out of engagement with the small recesses as the step of blind stacking an upper tray on a lower tray is nearly completed. As shown in Figure 16, the trays being blind stacked on one another are nearly parallel at the forward edge of the upper tray as it crosses the small recess, so engagement of the forward edge of the upper tray with the small recess is unlikely. However, should the trailing edge of the upper tray be lifted in relation to the lower tray, then the tapered wall portion 26 would guide the front edge smoothly over the opening of the small recess to enhance the free sliding movement during blind stacking of the upper tray onto the lower one. The third embodiment of the tray of the invention is shown in Figures 20-24. Substantially the same interengaging structure and outboard blind stacking structure are provided as previously described, with it being noted that the guide feet 30'' and guide recesses 31'' extend downwardly to a greater extent than their counterparts of the first embodiment and correspondingly the large feet and large recesses extend downwardly to a greater extent than their counterparts of the first embodiment. This greater depth is correlated to the provision of greater depth corner structure with respect to the second embodiment at the bottom and lower height corner structure at the top. As shown in Figure 21, the bottom surface 11'' terminates at a position spaced from each adjacent bottom corner, also evident from Figure 22. This provides inwardly facing corner flanges 33'' that are horizontally outward and vertically downwardly extending from the adjacent bottom surface 11''. The corner flanges are at the opposite terminal ends of each of the side walls 5'', 6''. With the tray of Figures 20-24, the downwardly extending corner structure provides the flat bottom surface 11'' sufficiently spaced above a support surface, such as a floor, so that a fork lift truck or the like may extend its forks easily beneath the tray without the provision of the chamfers 12 of the embodiment according to Figures 1,2 and 4. Additionally, the flat planar bottom surface 11'', particularly described with respect to the other embodiments provides, in Figures 20-24, the flat bottom surface that will, without interruption, engage a discontinuous support surface such as a roller conveyor to provide for full automation, with the depending corners being beyond the support of the narrower conveyor. Also, the flat bottom surface of the corner portions 34'' will engage the upper edge 25'' of the buttresses, at the near side, during stacking in the cross-nested position to function as previously described with respect to the first embodiment. Further, the corner flanges 33'' engage upper edges 25'' as the trailing edge of an upper tray slides across the lower tray at the completion of a blind stacking step. Accordingly, the trailing large feet and guide feet are correspondingly raised to clear the side wall allowing the large feet to engage within the channels along each end wall. In view of the similarity, as evidenced by like numerals, between the two embodiments, further description of the embodiment of Figures 20-24 is unnecessary. In addition to or in place of the far side, with respect to the operator during blind stacking, blind stacking features described above, the following outboard blind stacking features may be provided. As noted above, the interengaging structure providing high and intermediate level stacking is preferably all coplanar and in addition provides blind stacking functions at the far portion. The outboard blind stacking structure, for each of the end walls; the structure could be modified by placing the outboard structure inboard in an equivalent manner. In each of the embodiment of the trays constructed according to the present invention, the interengaging structure permits stacking of trays of one embodiment with another embodiment to attain the high and low stacked positions, except in the case of the trays constructed according to Figures 3, 5, 6 and 25 wherein only one height of stacking is attainable. Further, blind stacking is permissible between trays of each of the embodiments, but it is preferred that the outboard blind stacking structure be included to provide restraint against lateral shifting during blind stacking of trays. As mentioned, in cross-nesting the adjacent trays are 90 degree oriented. The trays of the first and fourth embodiments have a top edge along the side wall that is smooth or continuous and uninterrupted. However, according to another feature of the invention, the side walls of the trays constructed according to the second and fourth embodiments, as shown in Figures 22 and 25 respectively, have product retention fingers 40 and 41 respectively along each side wall. Thus, when the trays are cross-nested the product retention fingers penetrate the through passages in the bottom of the trays. Figures 3 and 23 show top views of the bottoms of the trays of the second and third embodiments respectively. The trays of the second embodiment are constructed with reduced size end and side walls than the trays of the third embodiment. Accordingly, it is preferred that in the use of a system of trays constructed according to the present invention, a first series of trays, for example constructed according to the second embodiment of the invention, would not be cross-nestable with a second series of trays, for example constructed according to the third embodiment of the present invention. Accordingly, the product retention fingers 40 of the first series and 41 of the second series have a different pattern or spacing relative to one another and between the side walls of the respective trays. Corresponding to this pattern is formed a matching pattern of elongated slots 42 and 43 as shown in Figures 3 and 23. When the trays within the first series are cross-nested with one another, the product retention fingers 41 penetrate the pattern of elongated slots 42 to allow the upper cross-nested tray to rest flat along the bottom tray, or with the bottom surfaces of the upper and lower trays substantially parallel. The same is true, of course, for the trays of the second series in that the product retention fingers 41 are patterned to project through the pattern of elongated slots 43 thus allowing cross-nested trays within the second series to form a cross-nested stack with the bottoms of adjacent trays being supported in substantially parallel relationship with one another. In order to prevent cross-nesting between trays of a first series and trays of a second series, the pattern of product retention fingers along the side walls of a first series of trays and corresponding elongated slots in the grid structure of the bottom of the first series of trays is different from that of the second series of trays. Accordingly, when a tray of a first series, for example a tray constructed according to the second embodiment, is attempted to be cross-nested onto a tray constructed according to the third embodiment, the product retention fingers along the side wall of the lower tray will penetrate certain ones of the through passages 9' in the bottom of the upper tray, but will not penetrate the elongated slots of the upper tray. As a result of the through passages being provided to extend outwardly only to a dimension that is less than the length between opposing ones of the product retention fingers, one row (side) of product retention fingers will penetrate corresponding ones of the through passages, but the other row (side) of product retention fingers will abut the bottom surface of the upper tray between where the through passages terminate and the end wall begins. Accordingly, cross-nesting of trays of one series with another series will result in the upper tray remaining in a canted position wherein the bottoms of the upper and lower trays are not parallel to one another. As a result, the mixing of one series of trays with another during cross-nesting will be readily apparent and the further cross-nesting of trays onto the canted stack of trays of different series will be prevented. The blind stacking feature of the trays constructed according to the present invention is accompanied by a blind unstacking feature. When many trays are stacked in a vertical stack that reaches a height exceeding that of the operator forming the stack, the blind stacking feature enables additional trays to be added to the stack so long as a front portion of a tray to be added to the stack can engage the top most tray of the stack to push the tray being added up over the top stacked tray and onto the stack. In the trays constructed according to the fourth embodiment of the present invention, features are included that allow for the blind unstacking of the trays. Thus, as with blind stacking, the trays constructed according to the fourth embodiment can be blind unstacked, or removed from a stack by grabbing only one side of the tray that faces the operator and manipulating the side that is grasped to disengage the stacking structures and slide the tray off the top of the stack, even when the stack has reached a height that is greater than the height of the operator handling the trays. Figures 26-30 show the details of the trays constructed according to the fourth embodiment of the present invention, and Figure 31 shows two such trays stacked on top of one another in a low stacked position. The trays are constructed with features similar to those of the trays of the other embodiments. The trays have a bottom wall 102, and opposed end walls 103 and 104 shown in Figures 26 and 28 respectively. A side wall 105 of the trays is shown in Figure 30 with the opposite side wall not shown, but being identical to side wall 105. The end and side walls are joined to the bottom wall of the container or tray to form an upwardly opening rectangular tray that is generally similar to the trays of the first three embodiments of the present invention. The trays shown in Figures 26-36 are of the same size as the trays of Figures 1, 2, 4 and 7-15 constructed according to the first embodiment of the invention, but the features directed to the blind unstacking capability of these trays can be included with the smaller size trays of the second embodiment shown in Figures 3, 5, 6 and 25 as well as with the trays of the other embodiments. As shown in Figure 26, the tray has large feet 121 with adjacent guide feet 130 and small feet 122. Large recesses 120 and small recesses 119 are provided to receive the large and small feet respectively. The feet 121 have bottom portions 123 that rest on the bottom of the large recesses when the trays are stacked as shown in Figure 31. As shown in Figures 26 and 28, a projection or lug 90 is shown that extends outwardly from each end wall along a bottom portion of the end wall. The projection 90 has a rounded bottom contour 91 that is preferably semicircular. The projections 90 are aligned along a center line of the tray midway between the side walls of the tray. Formed in the guide rail 138 along the top portion of each end wall is a slot 95 for receiving the projections 90 when the trays are in either of the high or low stacked positions. The slot 95 and recesses 119, 120 are best shown in Figures 27 and 29. Figure 30 shows a side view of one half of the trays constructed according to the fourth embodiment of the present invention with the other half of the tray being a mirror image of the half shown and the other side of the tray being identical to the side shown in Figure 30. Product retention fingers 140 are shown, which serve a similar purpose and function as the product retention fingers 40 shown in Figure 22 of the third embodiment of the present invention. Figures 31-36 show the blind unstacking structure of the trays according to the fourth embodiment as they are used in unstacking an upper tray from a lower tray of like construction. As shown in Figure 31, the large feet 121 at one side of the upper tray are supported within the large recesses 120 of a lower tray when the two trays are in the stacked position as shown. Also, the small feet 122 are supported in the small recesses 119 in the stacked position shown. In comparison to the close fit between the large and small feet and their respective recesses for the trays constructed according to the first four embodiments of the present invention, the large and small recesses 120 and 119 of the trays constructed according to the fourth embodiment of the invention are wider than the width of the foot by an offset distance as shown in Figure 31. As a result of the projections 90 being received within the slots 95, however, lateral or side to side shifting of an upper tray with respect to a lower tray is prevented. As shown in Figure 32, one method of blind unstacking the trays constructed according to the fourth embodiment involves grasping one side of an uppermost tray on a stack of trays and rotating or pivoting the upper tray relative to the lower tray about the large feet at the opposite side of the tray from where it is grasped. The bottoms 123 of the large feet rest in the bottom of the large recesses of a lower tray to enable the trays to be rocked or raised upwardly by the operator at the opposite side, which is ordinarily the only side accessible to the operator handling the uppermost tray in a tall stack of trays. As shown in Figure 33, the wider dimension of the large and small recesses allows the uppermost tray to be pulled toward the side that is raised, as shown in Figure 32. In this way after the projections 90 are disengaged from the slots 95 the upper tray is translated, or laterally shifted in the sliding direction even though the large feet 121 remain engaged in and supported within the large recesses 120. By raising one side of the upper tray as shown in Figure 32, the projections of the upper tray are lifted upwardly out of the slots 95. The angle at which an upper tray must be rotated about the large feet in the first pivoting step in unstacking an upper tray is determined by the position along the end wall of the projections 90. The projections are clear of the slots when an upper tray has been pivoted about the large feet on the large recesses of an adjacent lower tray at a fixed threshold angle, as shown in Figure 32. At this point, the small feet are still engaged within the small recesses 119. By pulling the upper tray toward the raised end, the small and large feet are shifted within their respective recesses as a result of the large and small recesses having a greater dimension than the width of the feet. Thus, the projections 90 become vertically misaligned with the slots 95 such that the projections are in position to engage the inner stacking rail 118, as shown in Figures 33 and 34. The extent of vertical misalignment between the projections 90 and slots 95 need only be 4.76 to 7.93mm (three-sixteenths to five-sixteenths of an inch), and the offset dimension between the width of the large and small recesses and the width of the large and small feet need only be 9.52 to 12.7mm (three-eighths to one-half of an inch). Once the upper tray is rocked into the position shown in Figures 33 and 34, the projections 90 engage the inner stacking rail 118 to enable the upper tray to be pivoted about a pivot axis extending between the projections to vertically disengage the large and small feet from their respective recesses as shown in Figure 35. The projections 90 are buttressed or supported by flanges 92 so that the projections can support the weight of the tray during the pivoting. As shown in Figure 34, the projections 90 extend outwardly a distance sufficient to engage the stacking rail 118, but not so far as to interfere with the sliding engagement between the upper and lower trays during the remainder of the blind unstacking procedure. Figures 35 and 36 show the upper tray in positions of unstacking the upper tray from the lower one. In Figure 35, the upper tray is shifted or moved to the left with respect to the lower tray a distance sufficient to engage the stacking structures of the upper and lower trays so that the orientation between the upper and lower trays is parallel. At this point, the large feet and small feet are vertically disengaged from the respective recesses and the side of the upper tray initially raised is shifted off of the vertical stack of trays a distance sufficient to enable an operator to thereafter pull the tray down off the top of the stack. Alternatively, the operator can continue the unstacking procedure by sliding the upper tray relative to the stack to the position shown in Figure 36 in order to expose a greater portion of the upper tray for pulling it downwardly off of a tall stack of trays. In Figures 37 and 38, a fifth embodiment of the present invention is shown. The trays or containers of Figure 37 have opposite end walls 203 and 204, a bottom wall 202 having holes or apertures 209 extending therethrough and at least one side wall 205 having elongated slots 206 extending therethrough. Opposite from side wall 205 is a wall 207 that is shorter in height than wall 205, but of a size sufficient to enable articles to be contained within the tray. The end wall structure of both end walls 203 and 204 is the same. Bales 210 are provided to swing between the two positions shown in order to provide two levels of stacking. In the lower stacked position, as shown between containers 219 and 220, projections 190 are received within slots 195. Accordingly, to unstack the trays, the upper tray can be first pivoted to disengage the projections 190 from the slots 195 and thereafter pivoted about the projections 190 to facilitate unstacking. In Figure 38, a container is shown that is of a slightly modified construction to the container shown in Figure 37, three different levels of stacking are obtainable, wherein containers 225 and 226 show one level of stacking and containers 226 and 227 show another level of stacking. A third level of stacking can be achieved by using the bales 210. As shown in Figure 38, projections 190 and slots 195 are provided to assist in unstacking the containers.

Claims: A unitary molded plastic bakery tray having a rectangular bottom (2), a pair of opposed side walls (5, 6) a pair of opposed end walls (3, 4) the side walls and the end walls being alternately connected to each other and to the bottom around the perimeter of the bottom to provide an upwardly opening rectangular tray, interengaging means (19, 20, 21, 22, 28) along the end walls to provide first and second different vertical stacking positions of like trays in a like orientation and a 180 degree rotated orientation which is about a vertical axis, perpendicular to the bottom, respectively, to hold therebetween bakery products of corresponding height during storage and transportation, and stacking rail means (31) along the upper edge of each of the end walls (3, 4) being spaced outwardly from and separate from the interengaging means, characterised by guide feet (30) at the opposite ends of each of the end walls adjacent the bottom, and outwardly spaced from and separate from the interengaging means, and recesses (19, 20) at opposite ends of each of the stacking rail means vertically aligned with the guide feet respectively freely to receive therein the guide feet to a nesting depth of like containers sufficiently for the interengaging means to provide each of the first and second stacking positions, and wherein each of the guide feet has a flat bottom portion and the stacking rail means (31) is an upper flat edge of each of the end walls (3, 4) constructed to receive and support thereon the flat bottom portions of the guide feet to maintain like orientation or said 180 degree orientation of like containers vertically spaced at a height greater than the first and second positions so that, when stacking containers overhead, without visual surveillance, the guide feet (30) engage the stacking rail means (31) slidably along the entire length of the stacking rail means to maintain the interengaging means spaced from each other and inoperative until the guide feet align with and interengage with the guide recesses. A tray according to claim 1, in which the guide feet (30) and the stacking rail means (31) engage during blind stacking in both the like orientation and said 180 degree orientation throughout the full length of the stacking rail means (31) to maintain the interengaging means inoperatively spaced apart. A tray according to claim 2, in which the bottom (20) and the side walls (5, 6) are constructed to provide linear sliding means slidably engaging continuously during stacking of the trays overhead, without visual surveillance, to support the portions of like containers located adjacent the person effecting the stacking while portions of like containers located remote from the person effecting the stacking are supported with respect to each other by the guide feet (30) and the stacking rail means (31). A tray according to claim 3, in which the bottom has a grid of vertically extending ribs (8) forming therebetween a plurality of at least similar small through passages (9) for aerating and lightness of the tray, the side walls, the end walls and the ribs all extend downwardly to terminal edges (10) that are coplanar to form a generally parallel horizontal bottom surface (11) interrupted substantially only by the through passages and presenting the lowermost structure of the tray, to constitute tray support means which provide effectively a planar surface, the pair of end walls are each higher than each of the side walls, and the exterior distance between the pair of side walls is substantially smaller than the interior distance between the end walls, so that the trays may be cross-nested in lower level stacking by having alternate trays in the vertical stack rotated about a vertical axis 90 degrees with respect to each other; and each of the side walls has buttress portions (17) extending from opposite ends of the side walls upwardly and outwardly toward the higher walls at a spacing wider than the distance between the side walls, the buttresses having top planar surfaces (25) to engage the planar bottom surface of a like top tray at the near side engagement during stacking overhead, without visual surveillance, of like oriented and 180 degree oriented trays. A tray according to claim 1, in which the interengaging means include supporting feet (21) adjacent the guide feet (30) and spaced inwardly thereof, the support feet (21) along one end wall (3) being adjacent and on one side of the guide feet (30) and the support feet on the other end wall (4) being adjacent and on another side of the guide feet, and the stacking rail means (31) having pockets of two depths (21, 22) to receive predetermined ones of the support feet in 180 degree and like orientation to provide the first and second different vertical stacking positions respectively. A tray according to claim 5, in which the stacking rail means further includes a guide rail (18) and a stacking rail (31) and a channel (28) formed between the rails; and the supporting feet extend into the channel (28) between the rails during stacking of the trays overhead, without visual surveillance, to prevent lateral movement of an upper tray in relation to a lower tray. A tray according to claim 6, in which the supporting feet extend a predetermined distance into the channel during blind stacking such that a terminal edge of the feet do not contact the bottom of the channel (28) whereby decreased frictional sliding resistance is maintained. A tray according to claim 1, including pivoting means (90) between the side walls to pivot the tray about a midportion of the tray to disengage the guide feet along one of the end walls from the corresponding ones of the guide recesses of a lower stacked tray; and means (95) along the end walls to receive the pivoting means of an upper stacked tray when upper and lower trays are vertically aligned in said stacked position and means (118) on the end walls to engage the pivoting means (90) of an upper stacked tray adjacent said means to receive the pivoting means such that the pivoting means of an upper tray is removed from the means to receive the pivoting means (95) in a lower tray and thereafter the upper tray is moved to position the pivoting means of the upper tray in engagement with the means to engage the pivoting means of the lower tray such that the upper tray is pivoted about the pivoting means from one of the side walls of the upper tray to disengage the guide feet (30) from the corresponding ones of the recesses (120) at the other of the end walls to permit the guide feet (30) slidably to engage the stacking rails (31) thus enabling the unstacking of the upper tray from a lower tray. A tray according to claim 8, in which the recesses (120) have a horizontal dimension wider than the corresponding dimension of the guide feet (30) such that an upper tray can be lifted at one of its side walls to cause the guide feet to engage a bottom of the recesses and pivot the tray bout the guide feet to disengage the pivoting means from the means to receive the pivoting means and thereafter the upper tray can be moved relative to the lower tray while maintaining engagement of the bottom of the guide feet with the bottom of the recesses to engage the pivoting means (90) of an upper tray on the means to engage the pivoting means (118) on a lower tray to pivot the upper tray about the pivoting means and disengage the guide feet from the recesses at the other of the end walls of the upper tray. A tray according to claim 8, in which the pivoting means is a projecting member (90) extending outwardly from a bottom portion of each of the end walls midway between the side walls and the means to receive the pivoting means is a slot (95) in the stacking rail means (31) along each of the end walls, each of the slots (95) being vertically aligned with each of the projecting members (90) when the trays are stacked in vertical alignment with one another. A tray according to claim 8, in which the guide feet and the stacking rail means engage during stacking and unstacking of the trays overhead, without visual surveillance, in both the like orientation and 180 degree orientation throughout the full length of the guide rail means (31) to maintain the interengaging means inoperatively spaced apart, the bottom (2) and the side walls (5, 6) are constructed to provide linear sliding means slidably engaging continuously during stacking and unstacking of the trays overhead, without visual surveillance, to support the near portions of like containers while the far portions of like containers are supported with respect to each other by the guide feet portions and the stacking rail means, the interengaging means include the support feet along one end wall being adjacent and on one side of the guide feet and the support feet on the other end wall being adjacent and on another side of the guide feet; and the stacking rail means having pockets of two depths to receive predetermined ones of the support feet in 180 degree and like orientation to provide the first and second different vertical stacking positions respectively; and the linear sliding means includes the side walls having a top edge portion adjacent the end walls and the bottom being recessed upwardly with respect to the corners to form a sloped bottom wall adjacent the corners joining the recessed bottom and the corners at a position spaced inwardly of the guide feet to engage the top edge portions of the side walls to raise the trailing edge of an upper tray during stacking overhead, without visual surveillance, of an upper tray on a lower tray permitting the guide feet to slide into a corresponding one of the recesses.

Inventors: STEIN ERIC D, TABLER CHARLES P, STEIN, ERIC D., TABLER, CHARLES P.
Applicants: BUCKHORN MATERIAL HANDLING, BUCKHORN MATERIAL HANDLING GROUP, INC.
Application year: 1989
Main classification: B65D21
IPC codes: B65D21