Abstract:
Four embodiments of a tray are disclosed for transporting and storing milk containers and for nesting the trays for their return trip to their origin.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 62/114,176 filed on Feb. 10, 2015 which is incorporated herein by reference in its entirety and made a part hereof. 
     
    
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    N/A 
       FIELD OF THE INVENTION 
       [0003]    The present invention relates to crates and trays for supporting product during transit, storage, and display and, in particular, trays for supporting bagged milk or plastic/paper containers of milk. 
       BACKGROUND 
       [0004]    Milk is normally delivered to the point of purchase either in plastic containers (bottles) or in plastic bags. Plastic bottles have recently been delivered to wholesale outlets in pallet quantities by using unique bottles and corrugated layer pads. The bottles and pads have been designed to support the weight of the bottles in a stack for delivery. Up to this point, bagged milk has only been able to be shipped in large quantities using metal dollies or shelves that can support the entire product weight. These shelving units are generally bulky and do not collapse well. In addition, the bagged milk tends to display poorly with the individual bags leaning off the shelves and looking disheveled. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention creates a nestable tray or crate system that supports the weight of the bottled or bagged milk. 
         [0006]    The trays condense for return shipping by nesting into one another. The trays also provide complete support for the containers&#39; weight as well as provide for better display customer presentation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings and attachments in which: 
           [0008]      FIG. 1  is a perspective view of a first embodiment of a tray of the present invention; 
           [0009]      FIG. 2A  is a side view of the tray of  FIG. 1  in operation; 
           [0010]      FIG. 2B  is a side elevation of a single tray of  FIG. 1 ; 
           [0011]      FIG. 3  is a side view of a plurality of the trays of  FIG. 1  nesting; 
           [0012]      FIG. 4A  is a perspective view of a plurality of a second embodiment of a tray stacked and in use; 
           [0013]      FIG. 4B  is a perspective view of a plurality of the trays of  FIG. 4A  nesting; 
           [0014]      FIG. 5  is a top plan view of the tray of  FIG. 4 ; 
           [0015]      FIG. 6  is a side elevation view of the tray of  FIG. 4 ; 
           [0016]      FIG. 7  is a view showing three separate stacks of the trays of  FIG. 4  with product; 
           [0017]      FIG. 8A  is a perspective view of a plurality of trays of a third embodiment stacked and in use; 
           [0018]      FIG. 8B  is a perspective view of a plurality of the trays of  FIG. 8A  nesting; 
           [0019]      FIG. 9  is a top plan view of the tray of  FIG. 8A ; 
           [0020]      FIG. 10  is a side elevation view of the tray of  FIG. 8A ; 
           [0021]      FIG. 11  is a view showing three separate stacks of the trays of  FIG. 8A  with product; 
           [0022]      FIG. 12A  is a perspective view of a plurality of a fourth embodiment of a tray stacked and in use; 
           [0023]      FIG. 12B  is a perspective view of a plurality of the trays of  FIG. 12A  nesting; 
           [0024]      FIG. 13  is a top plan view of the tray of  FIG. 12A ; 
           [0025]      FIG. 14  is a side elevation view of the tray of  FIG. 12A ; and, 
           [0026]      FIG. 15  is a view showing three separate stacks of the trays of  FIG. 12A  with product. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. 
       First Embodiment 
       [0028]    A first embodiment of the tray  10  is shown in  FIGS. 1-3 . Each tray  10  includes a top surface  11  and bottom surface  12 , opposed sides  22 , and opposed ends  23 . The top surface  11  of the tray  10  has a plurality of parallel flat surfaces  14  and a plurality of troughs each extending between opposed ends  23 , one of each of the plurality of troughs  15  being positioned between adjacent flat surfaces  14 . Thus, the flats  14  and troughs  15  alternate from one side  22  to the opposed side  22 . Each trough  15  includes inwardly tapered or inclined walls  18 , 19  and a substantially flat seating floor  20 . The flat surfaces  16 , 17  forming the sides  22  of the tray  10  are the same width. 
         [0029]    As shown in  FIG. 2B , the bottom surface  12  of the tray  10  has the reverse contours of the upper surface  11  of the tray  10 . The surfaces  11 , 12  are complementary of each other. Whereas a trough  15  is in the top surface  11 , a flat surface  14  is on the bottom surface  12  and visa versa. 
         [0030]    When two trays are stacked in a product storage or shipping position, the troughs and flats of one tray will extend in a direction perpendicular to the troughs and flats of the adjacent tray. That is, the ends of one tray are oriented 180° with respect to the adjacent tray. When adjacent trays have their ends rotated by 180 degrees they are said to be “confronting.” In this position, each of the flats  14  and troughs of the bottom surface  12  of the upper tray will extend between the opposed sides  22  of the lower tray crossing over all of the flats and troughs of the upper surface of the lower tray to form a plurality of enclosed, honeycomb chambers or vertical pockets  50  for both seating and protecting the milk M placed therein as shown in  FIG. 2A . The milk container has a height less than the height of the pockets so that the milk containers do not form part of the structural support for the stack of trays. The height of the stack of trays in a product storage position is the height of an individual tray multiplied by the number of trays in the stack. 
         [0031]    As shown in  FIG. 3 , when a plurality of trays are stacked in a nested or stored position without product, the flats and troughs of the trays are in alignment and the flats and troughs of the adjacent tray and in surface contact therewith such that the height of the stack of a plurality of n trays is equal to the height  51  ( FIG. 2A ) of an individual tray plus the thickness  52  of a tray multiplied by n−1. 
         [0032]    In one preferred form of the invention, the trays will be fabricated from a polymeric material and formed into the desired shape using standard polymeric forming techniques such as injection molding, thermoforming or the like. The trays can be made from any suitable polymeric materials such as polyolefins, polyamides, polyesters and the like. Preferred polyolefins include homopolymers and copolymers of ethylene, propylene, butene, hexene, octene and combinations of the same. In one preferred form of the invention, the trays are fabricated from a high density polyethylene (“HDPE”), polypropylene (“PP”), or polyethylene (“PE”). The polymeric material can also be foamed to reduce the density of the tray. One preferred tray has a dimension of approximately 98″ (end  23 ) by 40″ (side  22 ). The troughs  15  have a total width of 6″. Preferably, the trays are dimensioned to be transported on pallets such as shown in  FIG. 2A . 
       Second Embodiment 
       [0033]    The second embodiment of the tray  110  is shown in  FIGS. 4-7 .  FIG. 4A  shows the trays holding product M and  FIG. 4B  shows the trays empty and nested for storage or transport to their place of origin. 
         [0034]    Each tray  110  includes a top or upper surface  111  and bottom surface  112 , opposed sides  122 , and opposed ends  123 . The tray  110  has a checkerboard appearance, with a plurality of upper parallel flat surfaces  114  and a plurality of pockets  115 . Each pocket  115  includes inwardly tapered or inclined walls  118  and a substantially flat seating floor  120 . The underside or bottom surface  112  of the tray  110  has the reverse contours of the upper surface  111  of the tray  110 . Again, the bottom surface  112  of the tray  110  is substantially complementary to the top surface  111 . 
         [0035]    In this embodiment, trays are placed in a product storage position by orienting adjacent trays at 180° of one another. This configuration permits the milk bags M to be placed in the individual pockets  115  ( FIG. 4A ). When trays are positioned such that one tray confronts the adjacent tray so that flat surfaces  114  of the confronting trays  110  touch one another and the pockets  115  of the confronting trays face and align with one another, they form enclosed spaces or pockets  150  for both seating and protecting the milk M ( FIG. 4A ). When the trays are stacked in the same direction or orientation, they nest within one another as shown in  FIG. 4B . 
         [0036]    The tray  110  further includes an outer continuous perimeter rim  133  around the entire tray. The rim forms outer end lips  130  and outer side lips  131  to facilitate gripping and handling of the trays and add strength to the tray and lips. 
         [0037]    Again, like the first embodiment, the trays of the second embodiment will be fabricated from a polymeric material and formed into the desired shape using standard polymeric forming techniques such as injection molding, thermoforming or the like. The trays can be made from any suitable polymeric materials such as polyolefins, polyamides, polyesters and the like. Preferred polyolefins include homopolymers and copolymers of ethylene, propylene, butene, hexene, octene and combinations of the same. In one preferred form of the invention, the trays are fabricated from a high density polyethylene (“HDPE”), polypropylene (“PP”), or polyethylene (“PE”). The polymeric material can also be foamed to reduce the density of the tray. One preferred tray has a dimension of approximately 98″ (end  23 ) by 40″ (side  22 ). The troughs  15  have a total width of 6″. The tray  110  is approximately 20″ (end  123 ) by 48″ (side  122 ). The pockets  115  have a width of 9.2″ and a depth of 4.6″. The tray has a thickness of 6″ with the lip  130  being approximately 3.1″ from the top surface  111 . This permits the storage and transportation of 10 milk bags M per layer. 
         [0038]    The stacked, confronting trays are sized so they can be transported and stored on pallets P as shown in  FIG. 7 . 
       Third Embodiment 
       [0039]    The third embodiment of the tray  210  is shown in  FIGS. 8-11 .  FIG. 8A  shows the trays  210  in the product storage position with product therein and in use and  FIG. 8B  shows the trays  210  empty and nested for storage or transport to their place of origin. In the product storage position, adjacent trays are rotated 180° from one another, and in the nested position the trays have their ends in alignment or in the same orientation. 
         [0040]    Each tray  210  includes a top surface  211  and bottom surface  212 , opposed sides  222 , and opposed ends  223 . The tray  210  has a plurality of dividers  214  and a plurality of pockets  215  with a substantially flat seating floor  220 . 
         [0041]    The ends  223  of the tray  210  include a plurality of towers, or trapezoidal structures thereon having upwardly projecting towers  230  and downwardly projecting walls  231 . The towers  230  have angular edges or surfaces  224  and a flat top  225  edge while the projecting walls  231  have angular edges  226  and a flat edge  240 . In addition, a channel  244  for seating the tower  230  is formed in the tray by the edges  226  that terminates in a flat seat  227 . The trapezoidal structures are offset so that the edges and flat portions mate or communicate with one another differently when stacked and nested.  FIG. 8A  shows the trays in a product storage position with adjacent trays being positioned with their ends rotated by 180° from one another.  FIG. 8B  shows the trays in a nested position with the ends of the trays in alignment or in the same orientation. 
         [0042]    The towers  230  seat or are interconnected to the channels  244 . Interconnecting knobs  258  are formed in the upper surfaces or flat top  225  of the towers  230  for fitting within corresponding indents  259  or openings in the flat top  244 . This prevents sliding between the trays once aligned and seated. 
         [0043]    The tray  210  is not symmetrical. As a result, the trays seat with each other or cooperate with one another differently when adjacent trays face the same way or face different ways (turned 180 degrees). This configuration permits the milk bags M to be placed and stored in the pockets  215  while the towers protect them and support the tray above them when every other tray is rotated 180 degrees ( FIG. 8A ). 
         [0044]    Again, as with the prior embodiment, the trays  210  of the third embodiment will be fabricated from a polymeric material and formed into the desired shape using standard polymeric forming techniques such as injection molding, thermoforming or the like. The trays can be made from any suitable polymeric materials such as polyolefins, polyamides, polyesters and the like. Preferred polyolefins include homopolymers and copolymers of ethylene, propylene, butene, hexene, octene and combinations of the same. In one preferred form of the invention, the trays are fabricated from a high density polyethylene (“HDPE”), polypropylene (“PP”), or polyethylene (“PE”). The polymeric material can also be foamed to reduce the density of the tray. The tray&#39;s dimensions are shown in the Figures. The tray is 24″ by 40″ with the pockets being 9.88″ by 9.14″. The tray has a height of approximately 6.1″ with the towers having a height of roughly 12.2″. 
         [0045]    The stacked, confronting trays are sized so they can be transported and stored on pallets P as shown in  FIG. 11 . 
       Fourth Embodiment 
       [0046]    The fourth embodiment of the tray  310  is shown in  FIGS. 12-15 .  FIG. 12A  shows the trays in a product storage position holding product M and  FIG. 12B  shows the trays empty and nested for storage or transport back to their place of origin. 
         [0047]    Each tray  310  includes a top surface  311  and bottom surface  312 , opposed sides  322 , and opposed ends  323 . The tray  310  has a plurality of parallel flat surfaces  314   a  and dividers  314   b  and a plurality of pockets  315  with a substantially flat seating floor  320 . The underside or bottom  312  of the tray  310  can substantially have the reverse contours of the upper side  311 , with or without dividers  314 b, of the tray  310 . 
         [0048]    In the product storage position, adjacent trays are rotated 180° from one another ( FIG. 12A ). When every other tray is rotated 180 degrees, the flat surfaces  314   a  of the lower surface  312  of the upper tray contacts the flat surface  314   a  of the upper surface  311  lower tray and the pockets  315  of the upper tray face and are aligned with the pockets  315  of the lower tray to form enclosed spaces or pockets  315  for both seating and protecting the milk M. 
         [0049]    The tray  310  further includes an outer continuous perimeter rim  333  around the entire tray. The rim  333  forms outer end lips  330  and outer side lips  331  to facilitate gripping and handling of the trays and add strength to the tray and the lips. 
         [0050]    As in the other embodiments, the trays of the fourth embodiment will be fabricated from a polymeric material and formed into the desired shape using standard polymeric forming techniques such as injection molding, thermoforming or the like. The trays can be made from any suitable polymeric materials such as polyolefins, polyamides, polyesters and the like. Preferred polyolefins include homopolymers and copolymers of ethylene, propylene, butene, hexene, octene and combinations of the same. In one preferred form of the invention, the trays are fabricated from a high density polyethylene (“HDPE”), polypropylene (“PP”), or polyethylene (“PE”). In one preferred form of the invention, the tray is 20″ by 48″ with the pockets being 4.4″ by 9.1″. The tray has a height of the tray is 6.5″. 
         [0051]    The stacked, confronting trays are sized so they can be transported and stored on pallets P as shown in  FIG. 15 . 
         [0052]    The terms “first,” “second,” “upper,” “lower,” “top,” “bottom,” “above,” below,” etc. are used for illustrative purposes to associate relative positioning of elements to other elements only and are not intended to limit the embodiments in any way. The term “plurality” as used herein is intended to indicate any number greater than one, either disjunctively or conjunctively as necessary, up to an infinite number. The terms “joined,” “attached,” and “connected” as used herein are intended to put or bring two elements together so as to form a unit, and any number of elements, devices, fasteners, etc. may be provided between the joined or connected elements unless otherwise specified by the use of the term “directly” and/or supported by the drawings. 
         [0053]    While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims.