Abstract:
A top cap for a tray includes an upper surface for supporting goods and a lower surface including an attachment portion for locating the top cap relative to an upper portion of the tray.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The application claims priority to U.S. Provisional Application No. 62/023,869 which was filed on Jul. 12, 2014, U.S. Provisional Application No. 62/061,678 which was filed on Oct. 8, 2014, and U.S. Provisional Application No. 62/149,878 which was filed on Apr. 20, 2015. 
     
    
     BACKGROUND 
       [0002]    This disclosure relates to a container, and more particularly to a bakery tray having adjustable stacking heights and a device for stacking thereon. 
         [0003]    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 90 degrees. 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 90 degree 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. 
         [0004]    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. 
         [0005]    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 180 degrees 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 180 degree 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 
       [0006]    A top cap for a tray includes an upper surface for supporting goods and a lower surface including an attachment portion for locating the top cap relative to an upper portion of the tray. 
         [0007]    A tray includes a base and at least one wall extending upward from the base having an inner wall portion spaced from an outer wall portion by an upper wall portion. A notch extends through the inner wall portion, the upper wall portion, and the upper wall portion. 
         [0008]    A tray includes a base having a curvature with a first pair of walls and a second pair of walls extending upward from the base. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  illustrates an example tray according to a first embodiment. 
           [0010]      FIG. 2  illustrates a top perspective view of a top cap according to a first embodiment. 
           [0011]      FIG. 3  illustrates a bottom perspective view of the top cap of  FIG. 2 . 
           [0012]      FIG. 4  illustrates a perspective view of the top cap of  FIG. 2  positioned relative to the tray of  FIG. 1 . 
           [0013]      FIG. 5  illustrates a perspective view of the top cap of  FIG. 2  located on the tray of  FIG. 1 . 
           [0014]      FIG. 6  illustrates a perspective view of items located on the top cap of  FIG. 2  and the tray of  FIG. 1 . 
           [0015]      FIG. 7  illustrates a top perspective view of a top cap according to a second embodiment. 
           [0016]      FIG. 8  illustrates a bottom perspective view of the top cap of  FIG. 7 . 
           [0017]      FIG. 9  illustrates a perspective view of the top cap of  FIG. 7  positioned relative to the tray of  FIG. 1 . 
           [0018]      FIG. 10  illustrates a perspective view of the top cap of  FIG. 7  located on the tray of  FIG. 1 . 
           [0019]      FIG. 11  illustrates a perspective view of items located on the top cap of  FIG. 7  and the tray of  FIG. 1 . 
           [0020]      FIG. 12  illustrates a perspective view of a tray according to a second embodiment. 
           [0021]      FIG. 13  illustrates a front view of the tray of  FIG. 12 . 
           [0022]      FIG. 14  illustrates a side view of the tray of  FIG. 12 . 
           [0023]      FIG. 15  illustrates another side view of the tray of  FIG. 12 . 
           [0024]      FIG. 16  illustrates a bottom view of the tray of  FIG. 12 . 
           [0025]      FIG. 17  illustrates a top view of the tray of  FIG. 12 . 
           [0026]      FIG. 18  illustrates a perspective view of the tray of  FIG. 12  in a low stacked position on a similar tray. 
           [0027]      FIG. 19  illustrates a front view of the tray of  FIG. 12  in the low stacked position on the similar tray. 
           [0028]      FIG. 20  illustrates an end view of the tray of  FIG. 12  in the low stacked position on the similar tray. 
           [0029]      FIG. 21  illustrates another end view of the tray of  FIG. 12  in the low stacked position on the similar tray. 
           [0030]      FIG. 22  illustrates a top perspective view of the tray of  FIG. 12  in the high stacked position on the similar tray. 
           [0031]      FIG. 23  illustrates a front view of the tray of  FIG. 12  in the high stacked position on the similar tray. 
           [0032]      FIG. 24  illustrates an end view of the tray of  FIG. 12  in the high stacked position on the similar tray. 
           [0033]      FIG. 25  illustrates another end view of the tray of  FIG. 12  in the high stacked position on the similar tray. 
           [0034]      FIG. 26  illustrates the tray of  FIG. 12  stacked on an example dolly. 
           [0035]      FIG. 27  illustrates a perspective view of a tray according to a third embodiment. 
           [0036]      FIG. 28  illustrates a front view of the tray of  FIG. 27 . 
           [0037]      FIG. 29  illustrates a side view of the tray of  FIG. 27 . 
           [0038]      FIG. 30  illustrates another side view of the tray of  FIG. 27 . 
           [0039]      FIG. 31  illustrates a bottom view of the tray of  FIG. 27 . 
           [0040]      FIG. 32  illustrates a top view of the tray of  FIG. 27 . 
           [0041]      FIG. 33  illustrates a perspective view of the tray of  FIG. 27  in a low stacked position on a similar tray. 
           [0042]      FIG. 34  illustrates a front view of the tray of  FIG. 27  in the low stacked position on the similar tray. 
           [0043]      FIG. 35  illustrates an end view of the tray of  FIG. 27  in the low stacked position on the similar tray. 
           [0044]      FIG. 36  illustrates a top perspective view of the tray of  FIG. 27  in a high stacked position on the similar tray. 
           [0045]      FIG. 37  illustrates a front view of the tray of  FIG. 27  stacked in the high stacked position on the similar tray. 
           [0046]      FIG. 38  illustrates an example tray according to a fourth embodiment. 
           [0047]      FIG. 39  illustrates an example tray according to a fifth embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0048]    A bakery tray  10  is shown in  FIG. 1 . The bakery tray  10  generally includes a base  12 , front and rear walls  14  extending upwardly from front and rear edges of the base  12  of the tray  10 , and side walls  15 ,  16  extending upwardly from side edges of the base  12  of the tray  10 . The side walls  15 ,  16  include handles formed therein. Each of the front and rear walls  14  includes a pair of handles formed therein. 
         [0049]    Each of the side walls  15 ,  16  further include a pair of stacking feet  26  and a center projection  30  projecting downwardly. An upper edge of one side wall  15  includes a pair of stacking recesses  32  and a center recess  36  aligned with its corresponding center projection  30 . The upper edge of the other side wall  16  includes a pair of stacking recesses  34  and another center recess  36  aligned with its corresponding center projection  30 . The stacking feet  26  and the stacking recesses  32 ,  34  are spaced in such a way as to provide high and low stacking heights when the stacked trays  10  are rotated  180  degrees relative to one another, according to any of several known configurations. 
         [0050]    For example, on the side wall  16 , the feet  26  are spaced further outward (toward front and rear walls  14 ), while on the side wall  15 , the feet  26  (not visible) are spaced further inward (away from front and rear walls  14 ). The recesses  32  are spaced further outward, while the recesses  34  are further inward. This is one way of providing stacking at a high stack position in one orientation and at a low stack position in another (180 degree) orientation. 
         [0051]    The tray  10  of  FIG. 1  is prior art but together with top caps, such as those disclosed herein, form an inventive combination. 
         [0052]      FIG. 2  shows a top cap  50  according to a first embodiment. The top cap  50  is formed from a flat sheet of plastic into the shape shown, such as by thermoforming, vacuum forming, etc. Although the example shown is a single sheet, a twin-sheet thermoformed version is also contemplated. The top cap  50  as formed includes an upper panel portion  52  having a lip  54  extending downward from a periphery thereof. A plurality of alignment pylons  56  project upward from the periphery of the upper panel portion  52 , such as at each of the corners and from the middle of the front and rear edges and side edges. 
         [0053]    A plurality of reinforcement ridges  58  project upward relative to the upper panel portion  52 . Each reinforcement ridge  58  includes a pair of spaced-apart walls formed by the plastic sheet. As shown in  FIG. 3  (bottom view), a recess or elongated channel  60  is formed on the bottom surface of the top cap  50 , corresponding to the reinforcement ridges  58  ( FIG. 2 ) on top. As shown, the alignment pylons  56  are also hollow and open downwardly. 
         [0054]    As shown in  FIGS. 4 and 5 , the top cap  50  is sized and configured to be received on the tray  10 . The upper edges of the walls  14 ,  15 ,  16  of the tray  10  are received behind the lip  54  of the top cap  50 . This secures the top cap  50  stably on the tray  10 . 
         [0055]    As shown in  FIG. 6 , with the top cap  50  on the tray  10 , items  70  (such as boxes) can be placed on top of the top cap  50  without damaging any contents of the tray  10 . The alignment pylons  56  assist in retaining the items  70  on the top cap  50  during transport on the tray  10 . The top cap  50  allows the tray  10  to palletize with non-compatible products. In comparison, without the top cap  50 , the tray  10  can only stack with itself or on top of a flat even surface that is equal to or greater than the length and width of the tray  10 . 
         [0056]      FIG. 7  shows a top cap  80  according to a second embodiment. The top cap  80  is injection molded and fits within the footprint of the tray  10 , as shown in  FIG. 10 . The top cap  80  includes a base  82  having a plurality of feet  84 . The feet  84  should match or correspond to the feet  26  of the tray  10  in size and configuration. The top cap  80  may also include a center projection  86  corresponding to the center projection  30 . 
         [0057]      FIG. 8  is a bottom view of the top cap  80  of  FIG. 7 . A plurality of ribs  88  project downward from the base  82  for reinforcement, including a peripheral inner lip  90  projecting downward, but spaced inward from the periphery of the base  82 . Again, the spacing of the feet  84  and the presence of the central projection  86  would depend on the configuration of the tray  10 . 
         [0058]    As shown in  FIGS. 9 and 10 , the top cap  80  can be placed on the tray  10 , with the feet  84  received in the recesses  32 ,  34  of the tray  10  and the center projections  86  received in the center recesses  36 . The portion of the base  82  outward of the inner lip  90  contacts the upper edges of the walls  14 ,  15 ,  16  of the tray  10 . The inner lip  90  is received just inside the walls  14 ,  15 ,  16  of the tray  10  to help keep the top cap  80  in position on the tray  10 . 
         [0059]    As shown in  FIG. 11 , items  70  can be placed on the top cap  80  on the tray  10  for transport without damaging the contents of the tray  10 . The top cap  80  allows the tray  10  to palletize with non-compatible products. In comparison, without the top cap  80 , the tray  10  can only stack with itself or on top of a flat even surface that is equal to or greater than the length and width of the tray  10 . 
         [0060]      FIG. 12  illustrates a bakery tray  110  according to a second embodiment. The bakery tray  110  is similar to the bakery tray  10  except where described below or shown in the Figures. The bakery tray  110  generally includes a base  112 , front and rear walls  114  extending upwardly from front and rear edges of the tray  110 , and side walls  115 ,  116  extending upwardly from side edges of the base  112 . The side walls  115 ,  116  include handles formed therein. 
         [0061]    Each of the front and rear walls  114  includes an inner wall portion  118  and an outer wall portion  120  (or lip). The outer wall portion  120  is spaced outward of the inner wall portion  118  and extends downward from an upper wall portion  124  but not all the way to the bottom of the tray  110 . In the illustrated non-limiting embodiment, the outer wall portion  120  extends about halfway from the upper edge of the tray  110  toward the bottom of the tray  110 . 
         [0062]    A plurality of windows  144  are formed through the inner wall portion  118  below the outer wall portion  120 . The windows  144  may align with visual indicators on the bags of products (e.g. buns—not shown) to be placed in the tray  110 , so that the visual indicators indicate what kind of product (e.g. what kind of buns) are in the tray  110 . A plurality of ribs  122  connect the inner wall portion  118  to the outer wall portion  120  between the windows  144 . 
         [0063]    The outer wall portions  120  of the front and rear walls  114  also include one or more (two shown) logos  138  formed as part of the outer wall portions  120 . Each logo  138  includes generally vertical portions  140  or legs at the bottom. The logo  138  at least partially defines a notch  142  at the top of the logo  138 . The vertical portions  140  may be joined to the inner wall portion  118  via perpendicular vertical ribs  139 . The notches  142  help define the logo  138  and provide additional visibility into the tray  110 . The notches  142  extend all the way through the walls  114  (inner wall portion  118 , outer wall portion  120  and upper wall portion  124 ). 
         [0064]    The logos  138  are molded integrally with the remainder of the tray  110  (of some suitable plastic material). The logos  138  may also be tip branded after the tray  110  is molded. 
         [0065]    Each of the side walls  115 ,  116  further includes a pair of stacking feet  126  and a center projection  130  projecting downwardly. An upper edge of one side wall  115  includes a pair of stacking recesses  132  and a center recess  136  aligned with a corresponding center projection  130 . The upper edge of the other side wall  116  includes a pair of stacking recesses  134  and another center recess  136  aligned with a corresponding center projection  130 . The stacking feet  126  and stacking recesses  132 ,  134  are spaced in such a way as to provide different stacking heights when stacked trays are rotated 180 degrees relative to one another, according to any of several known configurations. 
         [0066]    For example, on the side wall  116 , the feet  126  are spaced further outward (toward front and rear walls  114 ), while on the side wall  115 , the feet  126  (not visible) are spaced further inward (away from the front and rear walls  114 ). The recesses  132  are spaced further outward, while the recesses  134  are further inward. This is one way of providing stacking at a high stack position in one orientation and at a low stack position in another (180 degree) orientation. 
         [0067]      FIG. 13  is a front view of the tray  10 .  FIGS. 14 and 15  are side views.  FIGS. 16 and 17  are bottom and top views of the tray  10 , respectively. 
         [0068]      FIG. 18  shows the tray  110  with an identical tray  110  stacked thereon with the tray  110  in the low stack position (i.e. the upper tray  110  rotated 180 degrees relative to the bottom tray  110 ).  FIG. 19  is a front view of the trays  110  of  FIG. 18 .  FIGS. 20 and 21  are side views of the trays  110  of  FIG. 18 . 
         [0069]      FIG. 22  shows the tray  110  with an identical tray  110  stacked on the tray  110  in the high stack position (i.e. the upper tray  110  in rotational alignment relative to the bottom tray  110 ).  FIG. 23  is a front view of the trays  110  of  FIG. 22 .  FIGS. 24 and 25  are side views of the trays  110  of  FIG. 22 . 
         [0070]    As shown in  FIG. 26 , the tray  110  (or a stack of trays  110 ) can be moved about on a dolly  100  having a deck  102  and wheels or castors  104 . 
         [0071]      FIG. 27  illustrates a bakery tray  210  according to a third embodiment. The bakery tray  210  is similar to the bakery tray  10  except where described below or shown in the Figures. The bakery tray  210  generally includes a base  212 , front and rear walls  214  extending upwardly from front and rear edges of the base  212 , and side walls  216  extending upwardly from side edges of the base  212 . 
         [0072]    The base  212  is curved and in the illustrated non-limiting embodiment the base  212  is convex. The base  212  curves convexly with a single curve from one side wall  216  to the other side wall  216  with a peak in a middle portion of the base  212 , in particular the center of the base  212  between the two side walls  216 . In another non-limiting embodiment, the curvature could extend between the front and rear walls  214 . Additionally, the curvature of the base  212  is continuous between the sidewalls  216 . The front and rear walls  214  are curved with the base  212 , such that each front and rear wall  214  has a peak at a middle portion between the two side walls  216 . 
         [0073]    Each of the front and rear walls  214  includes an inner wall portion  218  and an outer wall portion  219  (or lip). The outer wall portion  219  is spaced outward of the inner wall portion  218  and extends downward from an upper wall portion  221  but not all the way to the bottom of the tray  210 . In the illustrated non-limiting embodiment, the outer wall portion  219  extends about halfway from the upper edge of the tray  210  toward the bottom of the tray  210 . Gussets  220  connect the inner wall portion  218  to the outer wall portion  219  along the front and rear walls  214 . Logos  222  may be molded as part of the outer wall portion  219  and are also connected by gussets  224  to the inner wall portion  218 . The outer wall portion  219  provides larger surface area for branding in comparison to the small branding area of existing trays. 
         [0074]    The side walls  216  include a plurality of ribs  228  projecting outward from a planar interior wall portion. The ribs  228  are spaced upward from the lower edge of the side walls  216 . A pair of feet  232  and a center projection  234  project downward from the ribs  228  and outward from the lower portions of the side walls  216 . The upper ends of the side walls  216  include pockets for receiving the feet  232  and center projection  234 . One of the side walls  216  includes pockets  236  for receiving the feet  232  and a central pocket  238  for receiving the center projection  234  of an identical tray  210  stacked thereon. The side walls  216  include lower support portions  240  that contact the floor and are the lowest portions of the tray  210 . 
         [0075]    As shown in  FIG. 28 , the base  212  and front wall  214  curve upward to a peak in the middle and are convex upward. Lower support portions  240  of the side walls  216  support the base  212  on the floor. 
         [0076]    Referring to  FIGS. 29 and 30 , the side walls  216  have feet  232 ,  242  that are spaced differently to provide different stacking heights in a known manner. In the example shown, the feet  232  are spaced closer to the front and rear walls  214  than the feet  242 . Both center projections  234 ,  244  are in the center. 
         [0077]      FIG. 31  is a top view of the tray  210  showing a support surface  215 .  FIG. 32  is a bottom view of the tray  10  illustrating a plurality of ribs  213  that extend downward from the support surface  215  of the base  212  such that the base  212  forms a grid. In the illustrated non-limiting embodiment, the grid forms a diamond shaped pattern. 
         [0078]      FIG. 33  shows the trays  210  stacked in a low stacking height configuration. In this configuration, the upper tray  210  is oriented 180 degrees relative to the lower tray so that the feet can be received in the pockets. In this orientation, the upper tray  210  stacks lower on the lower tray  210 , so that the overall stacking height is reduced. More trays  210  would be stacked on the upper tray  210  the same way.  FIG. 34  is a front view of the trays  210  of  FIG. 33 .  FIG. 35  is a side view of the trays  210  of  FIG. 33 . 
         [0079]    In  FIGS. 36-37 , the trays  210  are in the high stacking height configuration. The upper tray  210  is oriented the same way as the lower tray  210  so that the feet are not received in the pockets and the upper tray  210  therefore stacks higher. This arrangement of stacking feet in bakery trays is well-known as are other configurations that provide multiple stacking heights, any of which could be used with the present invention. For example, the pockets may be arranged so that orienting the trays  210  the same way will provide the low stack position. Alternatively, the tray  210  could have a single stacking height, such that the trays  210  would stack at the same height in either orientation. 
         [0080]    In any of the stacked positions, because the base  212  of the upper tray  210  has the same contour as the base  212  of the lower tray  210 , the vertical height permitted for the product in the tray  210  is maintained. The curvature of the base  212  increases the area of the base  212  so that more product can be accommodated without increasing the outer footprint of the tray  210 . 
         [0081]    The curved base  212  is designed to increase the footprint of the tray&#39;s  210  internal dimensions without increasing the external footprint. This allows the user to fit product in each tray  210  with adequate clearance while maximizing area packout efficiency. The profile of the base  212  could alternatively consist of a single or any combination of curves, angles, steps, etc. geometry as necessary to suit the product going into the tray  210 . While the profiling is intended to increase the internal footprint surface area, using like-profiled trays  210  in a stacked configuration maintains internal product height clearance. 
         [0082]    In addition to the internal footprint, the profiled base  212  may also provide a structural benefit to the tray  210 . The structural benefit would provide decreased tray flexure and/or bowing which may cause product damage, internal fitment issues, or external fitment issues. 
         [0083]    Like the base  212 , the walls  214  can be profiled to accommodate product and clearance without increasing the external footprint. The wall  214  profile could consist of a single or any combination of curves, angles, steps, etc. geometry as necessary to suit the product going into the tray  210 . The wall profiling allows use of the multiple height positions and stacking configurations. 
         [0084]      FIG. 38  illustrates a tray  310  according to a fourth embodiment. The tray  310  includes a base  312 , a pair front and rear walls  314 , and a pair of side walls  316 . The base  312  includes a first half  312   a  and a second half  312   b  that slants upward from the sidewalls  316  to peak at a middle portion of the front and rear walls  314 . 
         [0085]    Each of the front and rear walls  314  and the pair of side walls  316  include an inner wall portion  318  and an outer wall portion  319  (or lip). The outer wall portion  319  is spaced outward of the inner wall portion  318  and extends downward from an upper wall portion  321  but not all the way to the bottom of the tray  310 . In the illustrated non-limiting embodiment, the outer wall portion  319  extends about halfway from the upper edge of the tray  310  toward the bottom of the tray  310 . 
         [0086]      FIG. 39  illustrates a tray  410  according to a fifth embodiment. The tray  410  includes a base  412 , a pair front and rear walls  414 , and a pair of side walls  416 . The base  412  includes a first half  412   a  and a second half  412   b  that slants upward from the front and rear walls  414  to peak at a middle portion of the sidewalls  416 . 
         [0087]    Each of the front and rear walls  314  and the pair of side walls  316  include an inner wall portion  318  and an outer wall portion  319  (or lip). The outer wall portion  319  is spaced outward of the inner wall portion  318  and extends downward from an upper wall portion  321  but not all the way to the bottom of the tray  310 . In the illustrated non-limiting embodiment, the outer wall portion  319  extends about halfway from the upper edge of the tray  310  toward the bottom of the tray  310 . 
         [0088]    Although the different non-limiting embodiments are illustrated as having specific components, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments. 
         [0089]    It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should also be understood that although a particular component arrangement is disclosed and illustrated in these non-limiting embodiments, other arrangements could also benefit from the teachings of this disclosure. 
         [0090]    The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.