Abstract:
The present invention relates to containers and systems of containers, for example, trays, that can be arranged at angles of 0 or 180° so that different height positions can be obtained; that include a glider to allow trays to move freely across one another under rapid use by a handler; and locking, securing and support mechanisms to ensure that the upper trays do not become disengaged during sudden movements, and to allow the trays to be stacked or nested, as appropriate for achieving different heights.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This invention is a continuation-in-part under 35 U.S.C. § 120 of co-pending application entitled “Ornamental Design for a Tray”, filed Jan. 30, 2006, naming Enrique Chávez Fernández and José Luis Alegría Formoso as inventors and having Attorney Docket No. 19677.004D2; and as a continuation-in-part of co-pending design Application No. (to be assigned), entitled “Ornamental Design for a Tray”, filed Jan. 30, 2006, naming Enrique Chávez Fernández and José Luis Alegría Formoso as inventors and having Attorney Docket No. 19677.004D3; and as a continuation-in-part of co-pending design Application No. (to be assigned), entitled “Ornamental Design for a Tray”, filed Jan. 30, 2006, naming Enrique Chávez Fernández and José Luis Alegría Formoso as inventors and having Attorney Docket No. 19677.004D4; and as a continuation-in-part of co-pending design Application No. (to be assigned), entitled “Ornamental Design for a Tray”, filed Jan. 30, 2006, naming Enrique Chávez Fernández and José Luis Alegría Formoso as inventors and having Attorney Docket No. 19677.004D5, which are herein incorporated by reference in their entireties. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to stackable containers or receptacles, and more specifically to stackable trays, for storing or transporting articles or products with different dimensions, which trays may be oriented and safely placed on top of each other in accordance with the dimensions of the product or article to be stored or transported.  
       BACKGROUND OF THE INVENTION  
       [0003]     It is known that one of the principal problems that currently exist in warehouses or transport vehicles is that of the space required to store or transport the largest possible quantity of articles or products without damaging them. Accordingly, users have developed, or have asked companies that are experts in the field to design, receptacles or containers that, depending on the user&#39;s individual needs, will allow transport and storage of items safely and securely.  
         [0004]     It is widely known in the field of packaging, storage, and transportation that space is saved when receptacles or containers are stowed or stacked. However, in order for stowing or stacking to be performed, consideration must be given to the subsequent handling of the receptacles or containers and to the type of articles or products that will be stored or transported in them, as well as to the subsequent storage and transport of the empty containers or receptacles. Some of the many factors that have been considered in the design of such receptacles or containers include the height of the articles or products to be stored, transported, or distributed; the weight of the product that the receptacle or container must bear; the characteristics of the place or places in which the articles or products will be stored, transported, or distributed; the conditions under which they will be handled by the operator or seller; the conditions of the road over which they will be transported; the durability of the containers; and their subsequent stacking after they have been emptied, including cleaning and washing, etc. In addition, the stability of the receptacles once stacked must be considered to prevent damage to the articles being transported.  
         [0005]     One of the principal techniques that have been used for the stacking of receptacles or containers is the so-called “nesting”technique, which consists of stacking the receptacles or containers at different angles so as to achieve a minimum height and a maximum height (see, for example, U.S. Pat. No. 3,780,905, of Ralph H. Herotzer; U.S. Pat. No. 3,934,724, of Lewis T. Johnson; U.S. Pat. No. 4,577,759, Pinckney Molded Plastics, Inc.; and U.S. Pat. No. 4,320,837, of James C. Carrol et al.). U.S. Pat. No. 4,936,458, of Tabler et al., describes a tray that can be nested at 90°, or stacked at 0° or 180°, through the use of feet and rails, and also describes a possible so-called “blind” stacking through the cooperation of insertion elements.  
         [0006]     U.S. Pat. No. 6,394,274, of Pinckney Molded Plastics, Inc. (Howell, Mich.), describes a bread tray that can be stacked on an identical tray that provides three levels of storage, which are obtained by rotating the trays to a given angle, depending on whether they are to be nested or stacked. However, this patent has the disadvantage that when sudden movements occur due to handling by the operator, the upper trays are easily separated from the lower trays, thereby causing damage to the product and rendering it unacceptable to the purchaser. Moreover, the trays utilize a very short sliding groove, which does not allow rapid alignment during the sliding operation, and also causes the trays to become easily separated. Further, the trays are not designed to withstand rough handling by the operators or the conditions that are present in trucks when they encounter potholes, earthfills, winding roads, etc. The result is that their useful lifetime is reduced significantly, and that the trays become separated while being transported by such trucks, which can cause damage to, and rejection of, the transported products. The superficial marks that the trays may contain in order to indicate to the operator the angle at which they are stacked tend to disappear rapidly as a result of the daily use and frequent cleaning that the tray must undergo, especially when the tray is used to transport food products that demand minimum levels of hygiene, thereby causing the operator to spend additional time determining whether a tray is stacked or nested. Furthermore, this tray does not have a mechanism that would, in the stacked position, allow the upper tray to be affixed securely to the lower tray. Additionally, the design of this tray does not allow a tray of a different width to be stacked on top of a lower tray, and does not contemplate the combination or alternation of trays of different widths during stacking.  
         [0007]     An additional disadvantage of the tray in U.S. Pat. No. 6,394,274 is that it runs the risk that the groove or sliding guide for the feet, as well as the sides and handholds, may become deformed or break within a short period of time, because of rough handling by the operator or even because of the weight of the product plus the weight of each stacked tray.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention is intended to overcome the above-mentioned shortcomings in the prior art. Thus, one goal of the invention is to provide a design that adds stability for a receptacle, container, or a stackable and/or nestable tray, for the storage or transport of the tray itself, or of products to be stored or transported in the tray. In one aspect of the present invention, this is achieved through a combination of structural elements, such as a locking mechanism and a securing mechanism, which prevent the trays from sliding out of balance with other trays in a stack and provide a stable and secure mechanism for transporting goods. In one aspect of the present invention, this is achieved by providing a tray with inner and outer grooves in the side of the tray (“guillotines”) to provide better support and securing of the containers in the nested position, thereby preventing them from becoming separated during rough or sudden movements while they are being stored or transported.  
         [0009]     Yet another goal of the present invention is to provide trays that lock in both the 0° and 180° positions relative to other trays in a stack, which allows for different heights to be achieved between the bases of two consecutive trays in a stack and accommodate goods of varying heights and sizes. Another aspect of the present invention is to provide trays that can interlock with existing trays to provide interchangeability to the user.  
         [0010]     Another aspect of the invention is to provide a tray that has a long useful lifetime even under harsh working or handling conditions. In one aspect of the invention, this combination is achieved giving consideration to the working conditions to which the trays would be subjected, such as dragging force, overload, the type of transport to be utilized, and the roads over which the trays would be transported, as well as careful or careless handling by various operators.  
         [0011]     Another aspect of the invention is to provide a tray, where the orientation (either in the stacking or nesting position) of two or more trays that are stacked can be readily identified, including doing so simply by sight or touch.  
         [0012]     Yet another goal of the present invention is to provide trays with a guiding mechanism, to provide a guide for allowing one tray to slide over another tray into either the stacked or nested position.  
         [0013]     Yet another goal of the present invention is to provide trays with varying dimensions, for example, that are narrower (but without their narrowness being a limiting factor), shorter or taller, or that can be stacked on top of other trays that are wider or larger, and that can also be combined or interleaved, in order to store products with smaller dimensions or different capacities. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is a right front perspective view of a tray in a short embodiment according to the present invention.  
         [0015]      FIG. 2  is a right side view of a tray in a short embodiment according to the present invention.  
         [0016]      FIG. 3  is a left side view of a tray in a short embodiment according to the present invention, which is a mirror image of the right side view.  
         [0017]      FIG. 4  is a front view of a tray in a short embodiment according to the present invention, which is a mirror image of the rear view.  
         [0018]      FIG. 5  is a top view of a tray according to the present invention.  
         [0019]      FIG. 6  is a bottom view of a tray according to the present invention.  
         [0020]      FIG. 7  is a right front perspective view showing two trays in a short embodiment of the present invention in the nesting position.  
         [0021]      FIG. 8  is a right front perspective view showing a combination of two trays of varying embodiments of the present invention in the nesting position.  
         [0022]      FIG. 9  is a right front perspective view showing a combination of two trays of varying embodiments of the present invention in the stacking position.  
         [0023]      FIG. 10  is a right front perspective view of a tray in a tall embodiment according to the present invention, showing additional elements of the present invention, as further described below.  
         [0024]      FIG. 11  is a right side view of a tray in a tall embodiment according to the present invention.  
         [0025]      FIG. 12  is a left side view of a tray in a tall embodiment according to the present invention, which is a mirror image of the right side view.  
         [0026]      FIG. 13  is a front view of a tray in a tall embodiment according to the present invention, showing additional elements of the present invention, as further described below.  
         [0027]      FIG. 14  is a top view of a tray according to the present invention, showing additional elements, as further described below.  
         [0028]      FIG. 15  is a bottom view of a tray according to the present invention, showing additional elements, as further described below.  
         [0029]      FIG. 16  is a right front perspective view showing two trays in a tall embodiment of the present invention in the nesting position.  
         [0030]      FIG. 17  is a right front perspective view showing an elongated embodiment of the tray of the present invention.  
         [0031]      FIG. 18  is a right front perspective view showing an alternative embodiment of the elongated embodiment of the tray of the present invention. 
     
    
       [0032]     Where the views described and shown in the drawings are mirror images of the reverse view, only one side will be described herein.  
       DETAILED DESCRIPTION  
       [0033]     As used herein, the word “tray” in intended not to be limiting, but is used interchangeably with the word “container”, “receptacle”, or the like.  
         [0034]     As used herein, two trays are “stacked” when they are placed, one on top of the other, at a 180° position relative to each other, resulting in a greater height (as compared to the “nested” position) between the floors of the trays.  
         [0035]     As used herein, two trays are “nested” when they are placed, one on top of the other, at a 0° position relative to each other, resulting in a lesser height between the floors of the trays.  
         [0036]     With reference now to the figures,  FIG. 1  shows that the tray  1  is designed in a manner similar to a box, including two sides of reduced height  2 , and a floor element  3  that may have various different design patterns, or no patterns, or which may be perforated or uniformly solid, as desired, although it is preferably perforated, so as to allow ventilation when the products consist, for example, of perishable items, bread, baked goods, etc., to facilitate cleaning of the tray, and to reduce the weight when several trays are stacked and carried on top of each other. Additionally, the tray of the present invention includes two sides of greater height  4  which may vary in height to accommodate different items to be transported in the trays (see, e.g.,  FIG. 8  showing two trays of the present invention having different heights).  
         [0037]     The sides of greater height  4  have upper and lower locking elements ( 5  and  6 , respectively) in order to allow an upper tray to be stacked. These locking elements  5  and  6  may be incorporated into various locations on the upper and lower sides of greater height  4  of the trays, and may be present in various and multiple patterns, such as facing each other in couples or solo, both as shown in  FIG. 1 . The upper and lower locking elements  5  and  6  may be pointed or rounded, or any other suitable shape.  
         [0038]      FIG. 1  also shows coupling element  7 , in which a glider  8  is positioned when an upper tray is stacked in the nesting position (see, e.g.,  FIGS. 7 and 8 ). Unlike the groove and leg mechanism disclosed in the prior art, the gliders  8  allow a user of the trays of the present invention to easily balance and slide one tray over another, such that the trays may be stacked or nested quickly and without the need to locate and align a groove of one tray with a leg or rail of another. Further, the glider  8  allows a tray to slide over an upper locking element  5  without prevent movement of one tray over another. The gliders may be triangular, or rounded in a half-moon shape, or any other suitable shape that allows for the trays of the present invention to be stacked easily and quickly. The present tray will preferably include an even number of gliders  8 , and most preferably utilize two or four gliders  8 , however any number of gliders may be suitable for use in the present invention that allows for easy stacking of two or more trays. The coupling elements  7  of the trays of the present invention should be complimentary to the shape of the gliders  8  used in a particular embodiment and should be present in the same number as the number of gliders  8  in a given embodiment.  
         [0039]     Trays may be stowed in the nested or stacked position, thereby providing spaces of different heights, depending on the required orientation of the trays in order to store products of different heights, and thereby enabling optimal use of the system for the safe and flexible placement of large or small products. The foregoing arrangement is also advantageous when towers of trays are created. Further, when the gliders  8  are positioned to fit in the coupling elements  7  in the nested position, it prevents the undesired sliding of the upper trays. Alternatively, in the stacked position (see, e.g.,  FIG. 9 ) the upper and lower locking elements  5  and  6  prevent sliding of the trays with respect to each other.  
         [0040]     The tray according to the present invention has at last two handholds or grips  9 , preferably one at the center of each side of greater height  4 , which are built and reinforced with vertical ribs and reinforcements  10 , spaced apart from each other so as to create a comfortable virtual gripping surface that allows the tray to be grasped safely at the center of its body. Additional handholds  11  comprised of vertical ribs  12  may be located on each side of reduced height  2 . The number of vertical ribs  10  and  12  may be varied according to the individual needs of a user of the trays.  
         [0041]     These vertical ribs and reinforcements  10  and  12  significantly increase the mechanical strength of the cross-section of the handholds  9  and  11 , thereby preventing the handholds from being deformed or broken if the trays are pulled apart such as by a hook, either individually or in the form of towers, which is an extremely common practice in working yards.  
         [0042]     Another characteristic of the tray according to the present invention is the increased load capacity, which is achieved through the proper reinforcement and distribution of the ribs  10  and  12  that form part of the structure of the four sides. The sides of greater height  4  are the ones whose function is to bear the weight of the towers of trays full of products.  
         [0043]     It should also be noted that, in one embodiment of the present invention, all of the internal lines  13  where the floor joins the sides and the corners may be slightly rounded ( FIG. 1  shows only two of them) so as to allow better cleaning of the tray because product wastes, grease, or dust may very often remain trapped in the corners if the corners consisted entirely of right angles, and to avoid the concentration of stresses and increase the load capacity and strength of the tray.  
         [0044]      FIG. 10  shows an alternative embodiment of the tray of the present invention where the sides of greater height  4  are taller than in the embodiment shown in  FIG. 1 . Such an embodiment allows for larger goods, such as bread loaves, cakes, etc., to be stowed and transported in the tray whereas the embodiment shown in  FIG. 1  would adequately stow smaller items, such as pastries and muffins. Additionally, either embodiment of the tray may include spikes  14  (shown in  FIG. 10 ) to prevent the contents of the trays from sliding out during transport or storage.  
         [0045]     In one embodiment of the present invention, it may be desirable for a user or operator to have trays with a configuration such that the orientation of the tray can be easily identified, because it significantly facilitates stacking, storage and movement of the tray and minimizes the possibility of error through the incorrect placement of a tray in relation to the tray immediately below it. As shown in  FIG. 2 , additional design elements of the present invention  15 ,  16 , and  17 , may be used to identify a tray&#39;s orientation with respect to another tray (i.e., in the stacked or nested position) by sight or touch. The design elements  15 ,  16  and  17 , may be raised or sunken (as shown in  FIG. 1 ), or hollow, open or solid, or any combination thereof such that a user of the tray of the present invention may determine which orientation a tray is in with respect to other trays in the stack (i.e., stacked or nested) easily by sight or touch. The design elements  15 ,  16  and  17  may be any suitable color, design, or trademark as desired by the user for visual effect. However, in the absence of any design elements in the tray of the present invention, the glider  8  position relative to the coupling element  7  can be used to identify the stacked position (see  FIG. 9 ) as it is apparent that the glider  8  is not resting in the coupling element  7 .  
         [0046]     In the sides of greater height  4 , structural open and closed design elements ( 18  and  19  show examples of open design elements) may be incorporated into the tray to provide strength and additional structure, or to conserve the amount of material used in the construction of the tray. Additionally, in different embodiments, more or less structural material (for example, molded plastic, polyurethane, etc.) and varying structural designs or configurations of structural designs present in the sides of greater height  4  may be used to vary the weight of the tray and to support different products. It should be understood that multiple configurations of the structural design elements are possible.  
         [0047]      FIGS. 1 and 2  also show inner  20  and outer  21  securing elements (the “guillotine”) that provide stability for stacked trays of the present invention when in the nested position. When a tray of the present invention is nested on top of another tray, the outer guillotine  21  rests in a “secured” position on top of the inner guillotine  20 . In this position, sliding and tipping of the trays is prevented during storage, handling and transportation. The inner guillotine  20  may vary in length and may be present in multiple locations on the sides of greater height  4  as desired by the user for increased or decreased contact between the inner guillotine  20  and the outer guillotine  21  of two or more stacked trays. Additionally, one or more columns  22  may be present to add structure and support to the inner guillotine  20  to accommodate varying weight to support upper stacked trays.  
         [0048]     In addition to the elements previously described,  FIG. 2  shows the additional element of a skid  28  that may be included on the bottom of the sides of greater height in the tray of the present invention. The skid  28  elevates a tray set on a flat surface (such as a floor or shelf) to prevent the contents of the tray from being in contact with contaminants such as dirt or liquids. In addition, the skid  28  allows a user to slide a tray more easily when it is in contact with a flat surface, and provides additional stability to the tray when it is stacked or nested with another tray of the present invention. Also, the skid  28  elevates the tray such that a forklift of other lifting mechanism can pick up a tray for transport from a flat surface. The skid may be continuous along the length of the tray, or may be present in shorter lengths as needed to support the weight of the tray and its contents.  
         [0049]      FIG. 2  also shows a glider  8  (only one shown) of the present invention. As discussed above, in the nested position, the glider  8  sits in the coupling element  7  to prevent movement of the tray in relation to others in the stack. The glider  8  also allows a user to easily slide one tray over another tray when trays are being placed in a stack.  
         [0050]     An advantage of the present invention is that the heights and depths with which the upper and lower locking mechanism  5  and  6 , the glider  8 , coupling element  7 , and the inner  20  and outer  21  guillotines, in particular, among others of the foregoing elements, have been designed as such to ensure their stability, because they cannot be loosened or “bounced” out of their channels as the result of an undesired jolt, such as one caused by a pothole in a road or by rough-surfaced highways.  
         [0051]     A further aim of the above-mentioned design is to ensure that the operator will be able to position the delivery, easily and rapidly, and ensure the smooth, continuous, and safe displacement of the parts of the tray that he is placing, in relation to the lower one, and also to ensure that it will be very difficult for multiple trays to be bounced apart or loosened, thereby causing breakage and loss of the product.  
         [0052]     The tray of the present invention may also include at least one support element  23  on the sides of reduced height  2  for balancing or supporting a tray of a different design that may be used interchangeably with the trays of the present invention. One such tray is disclosed in U.S. application Ser. No. 11/044,200. The support element  23  allows for a tray as shown and described in U.S. application Ser. No. 11/044,200 to be stacked and used in conjunction with the tray of the present invention. The support mechanism  23  may also be used in the elongated embodiments of the tray of the present invention ( FIGS. 19 and 20 ) to support one or more trays of the present invention. For example,  FIG. 17  shows an elongated tray with support mechanisms  23  for one or more elongated trays. In another example,  FIG. 18  shows and elongated tray with support mechanisms for one or more trays of the present invention. It is contemplated that any combination of the elongated trays disclosed in  FIGS. 19 and 20  may be stacked in combination with trays of the present invention. Further, the elongated trays disclosed in  FIGS. 19 and 20  may incorporate any or all of the features discussed with respect to the trays of the present invention.  
         [0053]      FIG. 4  shows a view of one side of reduced height  2  of the tray of the present invention. The vertical ribs  12  can be clearly seen in this view. Additionally, an alternative design element  24  may be included on either or both sides of reduced height  2  to provide a place to incorporate a label for goods or products that are transported in a tray.  
         [0054]      FIG. 5  shows the floor or base of the tray of the present invention. The pattern of various solid  25  and open  26  elements may be varied widely to provide support for heavier items (by increasing the composition of solid elements  25 ) or to reduce the weight (by increasing the compositing of open elements  26 ) in the floor pattern. Additional and optional open elements  27  may be included along the edges of the tray for additional ventilation or drainage as shown. Also shown in  FIG. 5  are alternative views of the vertical ribs and reinforcements  1 O, the inner guillotine  20 , and the upper locking elements  5  of the present invention.  
         [0055]      FIGS. 7 through 9  present varying systems of two trays of the present invention in the nested (see  FIGS. 7 and 8 ) and stacked (see  FIG. 9 ) positions.  FIG. 7  shows the combination stack of two trays of the shorter embodiment in the nested position, while  FIGS. 8 and 9  present systems wherein the combination of a tray in the shorter embodiment is used in conjunction with a tray in the taller embodiment of the present invention. As can be seen, even when two trays are nested (and thereby reduce the ability of the objects contained therein to be easily ascertained), there remains a gap between them on the side of lesser height that allows a user of the trays to readily view the contents of each tray. The sides of reduced height  2  may be modified by a broad curve that forms a wide window between the trays, such that when trays are stacked or nested, they allow the contents of each tray to be viewed easily, with no need to raise the top trays or lift them apart from each other in order to look inside them.  
         [0056]     The design of the receptacles or containers or trays allows varying working distances to be maintained when the receptacles or containers or trays are oriented differently in relation to one another (for example, in the 0° and 180° orientations). Thus, when the layout of the trays in relation to each other is changed, the separation between the trays allows for varying degrees of height to accommodate different products stored in the trays without affecting the ability of the trays to interlock and maintain their stability.  
         [0057]      FIGS. 10 through 16  show several views of the tray of the present invention in the tall embodiment. This embodiment may incorporate all of the elements previously described and therefore, will not be repeated herein. In additional to these elements, the tall embodiment of the tray shown in  FIGS. 10 through 16  also shows spikes  14  (as discussed above) incorporated into the side of lesser height to prevent the contents of the tray from sliding out. These spikes may be incorporated into the tall, short or elongated embodiments (shown in  FIGS. 17 and 18 ) of the present invention.  
         [0058]      FIG. 16  also shows a system assembly of two trays in the tall embodiment in the nested position. As discussed above, it is contemplated that any combination of tall or short trays may be incorporated into a system assembly of trays as needed to transport or store products.  
         [0059]     Further,  FIGS. 17 and 18  show elongated embodiments of the tray of the present invention. In these embodiments, the width of the tray between the sides of greater height is such that two of the narrower embodiment of the tray (described above) may be stacked or nested on top on one elongated tray.  FIG. 17  shows one variation of the this embodiment that is suited to accommodate the stacking or nesting of an identical elongated tray through the mechanisms described above.  FIG. 18  shows a second variation of this embodiment which preferably includes up to four additional support mechanisms  23  in the center of the sides of lesser height to support two of the narrower variations (either in the tall or short embodiments) of the tray of the present invention.  
         [0060]     Although all of the fundamental characteristics and features of the present invention have been described herein, with reference to specific embodiments of the invention, a degree of latitude in terms of other modifications, changes, and substitutions may be made in the foregoing description, and it will be apparent that on certain occasions, some of the characteristics of the invention will be employed without the corresponding use of other characteristics, without thereby departing from the scope of the invention as established. It should be understood that any such substitutions, modifications, or variations may be made by those skilled in the art without departing from the spirit or scope of the invention. Consequently, all modifications and variations are included within the scope of the invention, as defined by the following claims.