Abstract:
A tray includes a floor and a pair of opposed side walls, each having a cutout, one of which is larger to form the dropside. A pair of bail members are pivotably and slidably secured to opposed end walls. The bail members are supported by the end walls at a plurality of selected heights. The bail member is arranged to provide structural support to the dropside of a similar tray stacked thereon. The stiffness of the support is increased by the design of the bail member, which has a support portion with an elongated cross section. The elongated cross section is maintained in a vertical orientation when the bail member is in any of the stacking positions. In this manner, the dropside can have a large cutout without deflecting substantially during use.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates to a container, and more particularly to a tray having adjustable stacking heights.  
         [0002]     A common tray used in bakeries has two end walls for stacking and two shorter side walls for product visibility and to allow nesting. These trays typically nest by rotating alternate trays 90degrees. They are easy to blind stack (i.e. stack above your head where it is difficult to see any locating features). However, the requirement to nest the trays in a 90degree rotation makes the footprint of the nested trays larger than a single tray and results in a low nest ratio, which is limited by the height of the side walls.  
         [0003]     In some of the known trays, one of the side walls is shorter than the other, so that it is low enough for removing product even when the trays are stacked. This is commonly called a dropside version. This lower sidewall may also be called a window. When the trays are stacked, it is advantageous for the dropsides to align on the same side of the stack, so that product can be accessed from any of the trays from the same side. However, the dropside is weaker and deflects considerably more than the opposite side.  
         [0004]     Sometimes it is desirable for the trays to be stacked at a selected one of two selected heights, in order to minimize the stacking height to that required by the product in the trays at the time. This is usually accomplished by trays that stack at different heights when they are rotated 180degrees relative to one another. However, this means that the dropsides cannot be on the same side of the stack when the trays are arranged in alternating 180degree orientations in order to achieve one of the stack heights. Additionally, having two stack heights limits the ability to blind stack and the features to create this often cause the external dimensions of the tray to be larger. The larger tray size reduces the amount of full goods that can be shipped.  
       SUMMARY OF THE INVENTION  
       [0005]     A tray includes a floor and a pair of opposed side walls, each having a cutout, one of which is larger to form the dropside. A pair of bail members are pivotably and slidably secured to opposed end walls. The bail members are supported by the end walls at a plurality of selected heights. Thus, stacking orientation of the trays is independent of the stacking height, and the dropsides can be aligned at any stacking height. The bail member is arranged to provide structural support to the dropside of a similar tray stacked thereon. The stiffness of the support is increased by the design of the bail member, which has a support portion with an elongated cross section. The elongated cross section is maintained in a vertical orientation when the bail member is in any of the stacking positions. In this manner, the dropside can have a large cutout without deflecting substantially during use.  
         [0006]     Additionally, when the bail members are moved to a nesting position, the empty trays can be substantially nested within one another, thereby reducing the overall volume of the nested trays.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]     Other advantages of the present invention can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:  
         [0008]      FIG. 1  is a perspective view of a tray according to a first embodiment of the present invention.  
         [0009]      FIG. 2  is a perspective view of the tray of  FIG. 1  with a similar tray nested therein and nested in a similar tray.  
         [0010]      FIG. 3  is a perspective view of the tray of  FIG. 1  with a similar tray stacked thereon in a high stack position.  
         [0011]      FIG. 4  is a partial sectional view taken along lines  4 - 4  of  FIG. 3 .  
         [0012]      FIG. 5  is a perspective view of the tray of  FIG. 1  with a similar tray stacked thereon in a low stack position.  
         [0013]      FIG. 6 . is a partial perspective view of the tray of  FIG. 3  taken along lines  6 - 6 , showing movement of the bail member from the nest position to the high stack position.  
         [0014]      FIG. 7  is a partial perspective view of the tray of  FIG. 5  taken along lines  7 - 7 , showing movement of the bail member from the nest position to the low stack position  
         [0015]      FIG. 8  is a top view of the tray of  FIG. 1  with the bail members in the nest position.  
         [0016]      FIG. 9  is a perspective view of a tray according to a second embodiment of the invention showing the bail members in multiple positions.  
         [0017]      FIG. 10  is a perspective view of the tray of  FIG. 9  nested in a similar tray and with a similar tray nested therein.  
         [0018]      FIG. 11  is a perspective view of the tray of  FIG. 9  with a similar tray stacked thereon in a high stack position.  
         [0019]      FIG. 12  is a partial sectional view taken along lines  12 - 12  of  FIG. 11 .  
         [0020]      FIG. 13  is a perspective view of the tray of  FIG. 9  with a similar tray stacked thereon in a low stack position.  
         [0021]      FIG. 14  is a top view of the tray of  FIG. 9  with the bail members in the three possible positions.  
         [0022]      FIG. 15  is perspective view of a tray according to a third embodiment of the present invention.  
         [0023]      FIG. 16  is a perspective view of the tray of  FIG. 15  stacked on prior art trays and with a prior art tray stacked thereon. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0024]     A tray  10  according to a first embodiment of the present invention is shown in  FIG. 1 . The tray  10  includes a floor  12  and a pair of opposed end walls  14  extending upwardly from ends of the floor  12 . A first side wall  16   a  extends upwardly from a first side of the floor  12  and a second side wall  16   b  extends upwardly from a second side of the floor  12 . The first side wall  16   a  includes a first cutout  18  opening upwardly in a middle portion of the first side wall  16   a . The second side wall  16   b  includes a second cutout  20  or window opening upwardly in the middle portion of the second side wall  16   b.    
         [0025]     A pair of bail member  22  are pivotably and slidably secured at opposite ends to the end walls  14 . Each bail member  22  includes a support portion  24  extending from one end wall  14  to the other. The support portion  24  is connected at each end to a support arm  26  having an elongated pin  28  extending outwardly therefrom. Each pin  28  is trapped in a slot  30  through the end wall  14 . The pin  28  can slide freely from one end to the other of the slot  30  and can pivot slightly in the slot  30 . At least a portion of each end wall  14  includes an inner wall  36  and an outer wall  38 . The arm  26  is between the inner wall  36  and the outer wall  38  so that the pin  28  of the bail member  22  can be received in the slot  30  through the outer wall  38 . The inner wall  36  includes a high notch  54  and a low notch  56  for selectively supporting the support portion  24  at different heights (support portion  24  shown in phantom in the high notch  54  and the low notch  56 ).  
         [0026]     Each end wall  14  further includes an upper portion  40  and a lower portion  42 , set inwardly from the upper portion  40 . The inner wall  36  and the outer wall  38  form the upper portion  40 . The side walls  16   a, b  also each include an upper portion  44   a, b  set outwardly from a lower portion  46   a, b , respectively.  
         [0027]      FIG. 2  is a perspective view of the tray  10  with a similar tray  10 ′ nested therein and nested in a similar tray  10 ″. Referring to the uppermost tray  10 ′, in the nested position, the bail members  22 ′ are positioned such that the support portions  24 ′ are outside the upper portions  44   a,b ′ of the side walls  16   a,b ′. The lower portions  46   a,b ′ of the side walls  16   a,b ′ are fully nested between the upper portions  44   a, b  of the side walls  16   a, b  of the tray  10  below. The lower portions  42 ′ of the end walls  14 ′ are fully nested between the upper portions  40  of the end walls  14  of the tray  10  below. This minimizes the overall stacking height when the trays  10 ,  10 ′,  10 ″ are empty.  
         [0028]      FIG. 3  is a perspective view of the tray  10  with the similar tray  10 ′ stacked thereon. The bail members  22 ′ are positioned such that the support portions  24 ′ are supported in the high notches  54 ′ of the inner wall  36 ′. The lower portions  46   a,b ′ of the upper tray  10 ′ are only slight received between the upper portions  44   a,b  of the lower tray  10 .  
         [0029]      FIG. 4  is a partial sectional view taken along lines  4 - 4  of  FIG. 3 . As shown, the support portion  24  of the bail member  22  of the lower tray  10  is received within a channel  60 ′ formed on the underside of the floor  12 ′ proximate the cutout  20  in the second side wall  16   b ′. The support portion  24  of the bail member  22  contacts the floor  12 ′ of the upper tray  10 ′. Thus, the second side wall  16   b ′, which is weakened by the large cutout  20 ′, is reinforced by the bail member  22  of the tray  10  below.  
         [0030]      FIG. 5  is a perspective view of the tray  10  with the similar tray  10 ′ stacked thereon in a low stack position. The bail members  22 ′ are positioned with the support portions  24 ′ in the low notches  56 ′ (referring to the upper tray  10 ′, because the bail members in the lower tray  10  are positioned similarly, but not visible). When stacked thereon, the lower portions  46   a,b ′ of the side walls  16   a,b ′ of the upper tray  10 ′ are partially nested between the upper portions  44   a,b  of the side walls  16   a,b  of the lower tray  10 . This provides a reduced stacking height when the trays  10 ,  10 ′ are loaded with products that permit a lower stacking height.  
         [0031]      FIG. 6  is a partial sectional view of the tray of  FIG. 3  taken along lines  6 - 6 , showing movement of the bail member  22 ′ from the nest position to the high stack position. As shown, the support portion  24 ′ of the bail member  22 ′ is positioned outwardly of the upper portion  44   a ′ of the first side wall  16   a ′ when the bail member  22 ′ is in the nest position. The bail member  22 ′ can be moved from the nest position to the high stack position in the high notch  54 ′ of the end wall  14 ′ in the direction shown. The bail member  22 ′ is pivoted only slightly about the pin  28 ′ during the movement. The elongated pin  28 ′ is captured in the slot  30 ′ in the outer wall  38 ′ of the end wall  14 ′ (the slot  30 ′ and pin  28 ′ are shown in phantom, as they are behind the inner wall  36 ′ in this view). The slot  30 ′ includes a generally horizontal first portion  30   a ′ continuous with a sloped second portion  30   b ′, which is continuous with a generally horizontal, short third portion  30   c ′. During movement of the bail member  22 ′ from the nest position to the high stack position, the pin  28 ′ moves from one end of the first portion  30   a ′ to the opposite end of the first portion  30   a ′, adjacent the second portion  30   b ′. The pin  28 ′ is elongated horizontally in order to limit rotation of the pin  28 ′ within the slot  30 ′.  
         [0032]     As can be seen in  FIG. 6 , the support portion  24 ′ of the bail member  22 ′ has a vertically elongated cross section, which provides more stiffness in the vertical direction. Thus, the support portion  24 ′ of the bail member  22 ′ at least substantially maintains this orientation in the high stack position ( FIG. 6 ) and in the low stack position ( FIG. 7 ). As shown with reference to the bail member  22  of the lower tray  10  (not shown in  FIG. 6 ), the support portion  24  of the bail member  22  is received in the channel  60 ′ formed on the underside of the floor  12 ′ and contacts the floor  12 ′ to provide support.  
         [0033]      FIG. 7  is a view similar to that of  FIG. 6 , but showing movement of the bail member  22 ′ from the nest position to the low stack position, which is also partial sectional view taken along lines  7 - 7  of  FIG. 5 . During the movement, the pin  28 ′ slides through the first portion  30   a ′ of the slot  30 ′. The bail member  22 ′ is then pivoted so that the pin  28 ′ can slide through the second portion  30   b ′ of the slot  30 ′ to the third portion  30   c ′ where the pin  28 ′ returns to its horizontal orientation and, correspondingly, the support portion  24 ′ of the bail member  22 ′ returns to its vertical orientation in the low notch  56 ′. Since the pin  28 ′ and the support portion  24 ′ have both been moved down the same distance, the orientations of the pin  28 ′ and the support portion  24 ′ are unchanged. Again referring to the bail member  22  of the lower tray  10  (not shown in  FIG. 7 ), the support portion  24  is received within the channel  60 ′ and contacts the floor  12 ′ to support the floor  12 ′.  
         [0034]      FIG. 8  is a top view of the tray  10  of  FIG. 1  with the bail members  22  in the nest position outside the side walls  16   a,b.    
         [0035]      FIG. 9  is a perspective view of a tray  110  according to a second embodiment of the invention showing the bail members  122  in multiple positions. To the extent not otherwise described or illustrated, the tray  110  is identical to that of  FIG. 1  and like reference numerals will be used where possible, with a “ 1 ” preappended. The tray  110  includes side walls  1   16   a,b . In this embodiment, the bail members  122  are vertically aligned with the upper portions  144   a,b  of the side walls  116   a,b  when in the nest position. This decreases the overall footprint of the tray  110  in the nested position.  
         [0036]      FIG. 10  is a perspective view of the tray  110  of  FIG. 9  nested in a similar tray  110 ″ and with a similar tray  110 ′ nested therein. In this embodiment, the band  50  ( FIG. 1 ) of the first embodiment is removed so that the support portion  124  of the bail member  122  directly abuts the underside of the upper portions  144   a,b ′ of the side walls  16   a,b ′ and the outer surface of the lower portions  146   a, b ′.  
         [0037]      FIG. 11  is a perspective view of the tray  110  of  FIG. 9  in a high stack position with a similar tray  110 ′ stacked thereon. The support portion  124 ′ is supported in the high notch  154 ′.  
         [0038]      FIG. 12  is a partial sectional view taken along lines  12 - 12  of  FIG. 11 . Like the previous embodiment, the support portion  124  of the lower tray  110  is received within the channel  160 ′ in the underside of the floor  112 ′ and contacts the floor  112 ′ to provide reinforcement.  
         [0039]      FIG. 13  is a perspective view of the tray  110  of  FIG. 9  with a similar tray  110 ′ stacked thereon in a low stack position. The support portions  124 ′ are received in the low notches  156 ′.  
         [0040]      FIG. 14  is a top view of the tray of  FIG. 9  with the bail members  122  shown in the nest position (and shown in the two stack positions in phantom). In this embodiment, the support portions  124  of the bail members  122  are vertically aligned with the side walls  1   16   a,b  when in the nest position.  
         [0041]      FIG. 15  is perspective view of a tray  210  according to a third embodiment of the present invention. Except as otherwise illustrated or described, the tray  210  is identical to the tray  110 . Each bail member  222  includes a locating feature  225  projecting upwardly from the corners where the support portion  224  joins the arms  226 . The locating feature is generally perpendicular to the support portion  224  and arms  226 . The locating feature assists with blind stacking, by assisting the proper location of a prior art trays onto the tray  210 , as shown in more detail in  FIG. 16 , described below.  
         [0042]     Each side wall  214  includes a rail  227  extending upwardly from a middle portion thereof. Each rail  227  is aligned between the locating features  225  on opposite bail members  222 . Each side wall  214  further includes a pair of columns  241  projecting outwardly. A foot  243  is formed at the bottom of each column  241 . The foot is spaced outwardly from the side wall  214 . The rail  227  and feet  243  make the tray  210  more compatible with existing tray designs in a manner that will be described below.  
         [0043]      FIG. 16  is a perspective view of the tray  210  of  FIG. 15  stacked on a prior art tray  310  and with a prior art tray  310 ′stacked thereon. The feet  243  receive a rail  327  of the prior art tray  310 , such that the rail  327  is received between the feet  243  and the end wall  214 . The rail  227  (not visible) and the locating features  225  are received behind a foot flange  343 ′ of a prior art tray  310 ′ stacked on the tray  210 . This improves the stability of the stack and the compatibility of the tray  210  with the prior art trays  310 ,  310 ′.  
         [0044]     While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.