Patent Publication Number: US-7905353-B2

Title: Stackable containment trays and cases with slide latches

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     The present application is a Continuation-In-Part patent application of and claims the benefit of U.S. Provisional Patent Application Ser. No. 60/818,207, filed Jun. 30, 2006, entitled “Stackable Containment Trays” which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention pertains in general to stackable containment trays and cases that can be used for medical and dental equipment, devices, and instruments. Included as part of the case construction is a closing lid that includes novel slide latches. These stackable containment trays and cases can be used during autoclaving and for storage after proper sterilization. Each tray has a construction comprised of various component parts that are preferably riveted together and, when a removable closing lid is added, a containment tray becomes a containment case. The slide latches secure the closing lid to the uppermost tray of the stack of trays or to the single tray. 
     More specifically, the present invention pertains to the use of identical stacking rings wherein one stacking ring is arranged adjacent the upper edge portion of the tray and the other stacking ring is arranged adjacent the lower edge portion of the tray. Additionally, each tray includes a handle lock bracket and spaced therefrom a bail handle. The stackable containment trays are able to be interlocked by positioning the bail handles of the lower tray into the handle lock brackets of the upper, adjacent tray. 
     Whether for purposes of more efficient storage or for more convenience transport or perhaps for higher capacity sterilization, containment trays and cases can benefit from being stackable. The design considerations and issues then become design simplicity, reliability, and versatility, to mention a few. Another consideration is the stackability of the cases and the degree of ease or difficulty with which the assembled stack can be moved, stored, and autoclaved. There are also situations involving the use and handling of stacked trays or cases that would benefit from the stacked combination being secured together as a single unit. The present invention addresses these considerations and issues in novel and unobvious ways. 
     BRIEF SUMMARY OF THE INVENTION 
     A stackable containment tray for receiving discrete articles for storage and/or sterilization according to one embodiment of the present invention comprises a combination of two side panels, a floor supported by the two side panels, an upper stack ring, and a lower stack ring, a pair of opposed handle lock brackets, and a pair of opposed bail handles. The upper and lower stack rings are identical to each other and provide the stacking capability. The bail handle of one tray is able to interfit into the handle lock bracket of an upper tray, thereby enabling the stacked combination of trays to be locked together. Also disclosed is a sliding latch wherein a plurality of latches are attached to a closing lid for securing the lid to a tray. 
     One object of the present invention is to provide improved stackable containment trays and cases. 
     Related objects and advantages of the present invention will be apparent from the following description. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a perspective view of an assembled containment tray according to the present invention. 
         FIG. 2  is a perspective view of a closing lid suitable for connection to the  FIG. 1  containment tray. 
         FIG. 3  is a perspective view of the  FIG. 2  closing lid assembled onto the  FIG. 1  containment tray. 
         FIG. 4  is a perspective view of a side panel comprising one portion of the  FIG. 1  containment tray. 
         FIG. 5  is a perspective view of a floor comprising one component of the  FIG. 1  containment tray. 
         FIG. 6  is a perspective view of a plastic stack ring, two of which are used as part of the  FIG. 1  containment tray. 
         FIG. 7  is a perspective view of a handle lock bracket, two of which are used in the assembly of the  FIG. 1  containment tray. 
         FIG. 8  is a perspective view of a bail handle socket, four of which are used in the assembly of the  FIG. 1  containment tray. 
         FIG. 9  is a perspective view of a wire bail handle, two of which are used in the assembly of the  FIG. 1  containment tray. 
         FIG. 10  is a perspective view of a deeper side panel suitable for use in fabricating a containment tray according to the present invention. 
         FIG. 11  is a perspective view of a containment tray utilizing two of the  FIG. 10  side panels and providing a deeper tray as compared to the  FIG. 1  containment tray. 
         FIG. 12  is a perspective view of the  FIG. 11  containment tray with the  FIG. 2  closing lid. 
         FIG. 13  is a partial, end elevational view, in full section, illustrating the arrangement of components for the  FIG. 1  containment tray. 
         FIG. 14  is a perspective view of two  FIG. 1  containment trays stacked together. 
         FIG. 15  is a perspective view of one  FIG. 11  containment tray stacked together with one  FIG. 1  containment tray. 
         FIG. 16  is a perspective view of one  FIG. 11  containment tray stacked together with two  FIG. 1  containment trays. 
         FIG. 17  is a perspective view of the  FIG. 16  stacked combination with the  FIG. 2  closing lid. 
         FIG. 18  is a partial perspective view of the  FIG. 16  stacked combination. 
         FIG. 19  is a perspective view of a closing lid including slide latches in a closed condition according to the present invention. 
         FIG. 20  is a perspective view of the  FIG. 19  closing lid with the slide latches in an open condition. 
         FIG. 21  is a perspective view of one slide latch in a closed condition. 
         FIG. 22  is a perspective view of the  FIG. 21  slide latch. 
         FIG. 23  is a top plan view of the  FIG. 21  slide latch. 
         FIG. 24  is a side elevational view, in full section, of the  FIG. 21  slide latch as viewed along line  24 - 24  in  FIG. 23 . 
         FIG. 25  is a perspective view of a slide latch in an open condition. 
         FIG. 26  is a perspective view of the  FIG. 25  slide latch. 
         FIG. 27  is a top plan view of the  FIG. 25  slide latch. 
         FIG. 28  is a side elevational view, in full section, of the  FIG. 25  slide latch as viewed along line  28 - 28  in  FIG. 27 . 
         FIG. 29  is a perspective view of a slide latch body comprising one component part of the  FIG. 21  slide latch. 
         FIG. 30  is a perspective view of the  FIG. 29  slide latch body. 
         FIG. 31  is a perspective view of a slide member comprising one component part of the  FIG. 21  slide latch. 
         FIG. 32  is a perspective view of the  FIG. 31  slide member. 
         FIG. 33  is a perspective view of a slide lip comprising one component part of the  FIG. 21  slide latch. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. 
     Referring to  FIGS. 1 ,  2  and  3 , there is illustrated a containment tray  20  that is constructed and arranged according to the present invention. A suitable closing lid  21  for tray  20 , in order to thereby create a containment case  22  (see  FIG. 3 ), is illustrated in  FIG. 2 . Closing lid  21  includes a generally rectangular, vacuum-formed plastic body  23  and four slide latches  24 . Each slide latch  24  is securely attached to an upper surface  25  of the body  23  adjacent one of its four sides by the use of mounting spuds in cooperation with a matching hole pattern in the upper surface at each slide latch  24  location. Each hole is countersunk from the back side or inner surface of the lid  21 . Upper surface  25  defines a plurality of flow holes for the passage of steam and/or other sterilant. Each slide latch  24  includes a body  26  that is attached to surface  25  and a slide member  27  that moves through the body  26  toward and away from body  23 . The position of slide lip  28  can be controlled by the manual engagement and movement of slide button  29 . As will be described, the mating tray  20  includes corresponding and aligned openings, four total (see  FIG. 1 ), that are constructed and arranged to receive the lip  28  of the mating slide latch  24 . This mechanical engagement securely attaches the lid  21  to the tray  20  in order to create containment case  22 . 
     With continued reference to  FIG. 1 , the fully assembled containment tray  20  is a combination of individual component parts that are separately fabricated and then assembled together to create the tray  20  construction that is illustrated. The component parts of tray  20  are illustrated in  FIGS. 4-9  and include two side panels  34 , a floor  35 , two unitary plastic stack rings  36 , two handle lock brackets  37 , four bail handle sockets  38 , and two wire bail handles  39 . The two side panels  34  are arranged to face each other and the floor is received therein. One stack ring  36  is at or adjacent the base or bottom of the tray and in cooperation with the corresponding side panel supports the edge of floor  35 . The other stack ring  36  is at or adjacent the open upper end of the tray for receiving lid  21 . One handle lock bracket  37  is attached at one end of tray  20  and the other handle lock bracket  37  is attached in a similar and aligned fashion at the opposite end of the tray  20 . Two bail handle sockets  38  are attached in a spaced-apart manner at one end of the tray and are arranged to receive one of the two wire bail handles  39 . Each bail handle  39  is able to be flexed so as to shorten the distance between its free ends  39   a  and  39   b . This in turn permits the free ends of the bail handle to be inserted into the corresponding spaced pair of bail handle sockets  38 . The other two bail handle sockets  38  are attached at the opposite end of tray  20  in a similar and aligned fashion. The other wire bail handle  39  is assembled into this opposite pair of sockets  38  in the same fashion. 
     As described herein, the attachment of the pair of side panels  34  via the lower stack ring  36  and/or the upper stack ring  36 , creates a tray frame with two sides and two ends. Each end includes one section  42   a  and one section  42   b  and receives one handle lock bracket and one bail handle  39  with sockets  38 . 
     The preferred material for each side panel  34  is metal and the preferred fabrication method or technique is a metal stamping operation followed by a forming or bending operation. The preferred material for floor  35  is metal and the preferred fabrication method or technique is a metal stamping. The preferred material for each stack ring  35  is plastic and the preferred fabrication method or technique is a molding operation. The preferred material for each handle lock bracket  37  is plastic and the preferred fabrication method or technique is a molding operation. The preferred material for each bail handle socket is plastic and the preferred fabrication method or technique is a molding operation. The preferred material for each wire bail handle  39  is metal and the preferred fabrication method or technique is a bending operation. 
     As for the overall assembly or fabrication of tray  20 , once all of the required components parts are available, the first step is to assemble the floor  35  and the two side panels  34  into a subassembly. Each side panel  34  (see  FIG. 4 ) includes a first end section  42   a  and opposite thereto a second end section  42   b  with an extending or offset rivet flange  43 . Each end section  42   a  and  42   b  is substantially flat and generally perpendicular to the side section  42   c . As would be understood, when the second side panel  34  is turned into a facing orientation with the first side panel, the end sections are reversed such that there is an offset rivet flange at each end of the tray being assembled. Further, the joining of the two end sections, one from each side panel  34 , creates each end of the tray. Each side panel  34  further includes a floor-support flange  44   a  along the length and a floor-support flange  44   b  along each width side. With the two side panels facing each other, but not yet connected, the floor  35  is positioned onto flanges  44   a  and  44   b  of both side panels. Next, the two side panels  34  are pushed together and riveted to each other at each end using the offset rivet flange  43 . Pilot holes, not shown, are drilled for the rivets. The floor is effectively clamped in position by the two side panels (see  FIG. 13 ). 
     The next step is to take the side panel  34  and floor  35  subassembly and position it on top of the lower stack ring  36  (see  FIG. 13 ). Each stack ring  36  includes an inner support shelf  45  and an upright wall  46 . These two portions define an interior right angle corner  47  that receives the corner edge of the corresponding side panel  34  (see  FIG. 13 ). The next step is to securely and tightly rivet together the floor  35  with each side panel  34  and with the corresponding support shelf  45 . A suitable riveting location is identified in  FIG. 13  by broken line  48 . Each stack ring  36  includes opposite end notches  36   a  and opposite side notches  36   b  for clearance so that each slide latch lip  28  can engage each slot  30 . 
     The next step in the assembly procedure is to place the upper stack ring  36  on the upper edges of the side panels  34  such that support shelf  45  rests on the upper flanges  49   a  (of each side section  42   c ) and  49   b  (of each end section  42   a  and  42   b ). These two components are then riveted together, generally at the location defined by broken line  50 . Since there is not any reference surface to abut up against or align to, such as the use of corner  47 , a removable spacer or shim can be used for proper positioning of the upper stack ring  36 . The thickness of the spacer or shim corresponds precisely to the thickness of upright wall  46 , as depicted in  FIG. 13 . This ensures the proper alignment and positioning for future stacking of containment trays. 
     The next step is to rivet each handle lock bracket  37  to the joined end sections of the two side panels  34 . The same approach and technique is applied to each bail handle socket  38 . However, due to the stiffness of each bail handle  39 , the preliminary step is to insert each end of the bail handle into its corresponding socket  38 , prior to riveting or otherwise attaching the sockets  38  (with installed handle) to the end. While riveting is considered to be the preferred connection method due to the anticipated weight of the articles to be placed in the trays and cases, ultrasonic welding is another connection option. 
     With continued reference to  FIG. 1 , the assembled containment tray  20  is ready for the receipt of any discrete articles that need to be transported, stored, sterilized, etc. The preferred method of lifting, handling, and transporting is to pivotally raise each bail handle  39 , as illustrated, noting that there is sufficient clearance between the bail handle and upper stack ring  36  for the fingers of the user to be inserted, similar to how a basket or tray might be lifted and carried. When not manually raised, the bail handles are free to pivot or drop to a downward or depending (hanging) orientation. 
     With continued reference to  FIG. 4 , each side panel  34  includes one oblong slot  30  for receipt of a corresponding slide latch lip  28 . The end sections  42   a  and  42   b  that provide approximately one-half of the tray&#39;s end length each include an approximately one-half length open oblong slot  54 . As the two side panels are assembled together, enclosed end slots  30  are created by the mating of facing end sections  42   a  and  42   b  at one end and  42   b  and  42   a  at the opposite end. These end slots are constructed and arranged to receive a corresponding slide latch lip  28  as part of securing the lid  21  to the tray  20  in order to create containment case  22 . 
     One variation for tray  20  of  FIG. 1  is to increase the tray depth. This is achieved by designing each side panel  58  with greater (i.e., increased) depth (see  FIG. 10 ). Side panel  58 , as illustrated in  FIG. 10 , is identical to side panel  34  in every respect except for its height or depth. In the preferred embodiment, side panel  58  is approximately twice the depth of side panel  34 . The new tray  59  that is created from side panels  58  maintains the same length and width dimensions as tray  20 . This permits the deeper tray  59  (see  FIG. 11 ) to use all of the same (other) component parts, changing only the side panels  58 . As such, tray  59  uses the same floor  35 , the same plastic stack rings  36 , the same handle lock brackets  37 , the same bail handle sockets  38 , and the same wire bail handles  39 . Further, the same assembly technique and method is used for the assembly of these component parts in order to create tray  59 . Further, the same closing lid  21  is able to be used on tray  59  in order to create containment case  60 , as illustrated in  FIG. 12 . 
     One of the features of the present invention is the ability to stack one tray one top of another tray and the ability to add a closing lid to the top tray in the stack in order to create a case. This stackable capability is derived from the specific shape of each plastic stack ring  36  wherein the depending outer wall  63  of the upper tray rests on outer support shelf  64  of the lower tray up against upright wall  46 . Inner support shelf  45  and outer support shelf  64  are on opposite sides of upright wall  46 . Inner support shelf  45  and outer support shelf  64  are coplanar and are perpendicular to upright wall  46  and to depending outer wall  63 . The distance between the outer surface of wall  46  and the outer surface of wall  63  is substantially equal to the thickness of wall  63 . The cross sectional illustration of  FIG. 13  depicts the stack ring  36  geometry that permits a lower stack ring of one tray to fit onto an upper stack ring  36  of the adjacent tray. This stackable feature capability is not limited to any particular number of trays and it is not limited to the depth of the trays that are selected for the stack. Trays  20  and  59  can be mixed in the stack in any number and in any order. The only practical limitation as to the number of trays depends on the articles to be placed within each tray and the overall combined weight of the stacked trays with the articles placed therein. As noted, a closing lid  21  can be used on the top tray of the stack and various examples of stacked tray arrangements or combinations are illustrated in  FIGS. 14-17 . 
     Another feature of the present invention is the ability to effectively lock the stacked trays together, as detailed in  FIG. 18  and as illustrated in  FIGS. 14-17 . This locking feature involves pivoting a bail handle  39  of a lower tray upwardly into the handle lock bracket  37  of the immediately upper or adjacent stacked tray. The center portion  65  of the bail handle has a wire diameter that allows it to fit snugly into the clearance channel  70  that is defined by the combination of shelf  66  and the two spaced-apart detent tabs  67 . The pair of gusset protrusions  68  that are illustrated prevent pushing the bail handle  39  too far inwardly. This in turn spaces the bail handle away from the back panel  69  of the handle lock bracket  37  a sufficient distance (i.e., spacing) so that it is easy to grasp the bail handle  39  and pull it in a direction away from the end of the tray so as to disengage the bail handle from its engaged or locked position within the corresponding handle lock bracket  37 . Although this engagement of bail handles  39  into a corresponding and cooperating handle lock bracket  37  is only illustrated at one end of the stacked tray arrangement, it is to be understood that a similar arrangement exists at the opposite end so as to prevent separation of the stacked trays, even partially. In order to avoid critical dimensions and tolerancing, the use of plastic for the handle lock brackets  37  provides some “give” in terms of slight movement or deflection permitted for each of the spaced-apart detent tabs  67 . 
     Referring to  FIGS. 19 and 20 , a slightly different closing lid  80  is illustrated with four slide latches  24 . One reason to include closing lid  80  is to convey the understanding that the tray construction disclosed herein can be used in combination with closing lids of different styling and construction. The raised rib sections  81  of various dimensions and shapes provide structural rigidity to the molded plastic construction of lid  80 . These structural rib sections  81  include a curved portion  81   a  disposed around the sides and the button end of each slide latch. These raised rib sections also provide a way of safely stacking completed cases on top of each other without putting weight on or interfering with the individual slide latches  24 . 
     Consistent with what has been described for closing lid  21 , each slide latch  24  includes a plastic body  26  that is ultrasonically welded to the surface of lid  80 . The slide latches  24  of  FIG. 19  are positioned in what constitutes a closed condition if assembled to a tray. In the illustrated position, the slide lid  28  is drawn inwardly toward the body of the lid  80  and would be received by a corresponding and cooperating slot  30  when the slide lip  28  is in this position and the lid is applied to a tray. In the  FIG. 20  illustration, the slide member  27  has been moved outwardly so as to constitute an open condition if assembled to a tray. If lid  80  of  FIG. 20  is assembled to a tray, each slide lip  28  is positioned outwardly and does not engage its corresponding and cooperating slot  30 . In this condition, the lid  80  is able to be lifted off of the tray, i.e., to open the case. 
     Referring now to  FIGS. 21-28 , the details of slide latch  24  are illustrated, first in the closed condition of  FIG. 19  (see  FIGS. 21-24 ) and thereafter in the open condition of  FIG. 20  (see  FIGS. 25-28 ). As already described, each slide latch  24  includes a slide body  26 , slide member  27 , slide lip  28 , and slide button  29  which is a part of the unitary slide member  27 . Preferably, the slide body  26  is molded as a unitary plastic component to enable the described ultrasonic welding to the plastic of the upper surface of the tray, either tray  21  or tray  80 . The slide member  27 , including slide button  29  as part of its unitary construction, is preferably molded from plastic. The slide lip  28  is a unitary component that can be fabricated from plastic, but preferably from metal. 
     With continued reference to  FIGS. 21-24 , the slide latch  24  in the closed condition is illustrated in greater detail. Slide latch body  26  (see  FIGS. 29 and 30 ) includes four plastic spuds  84  for securely attaching the body  26  to the upper surface of the tray. The upper surface  25  includes a four-hole pattern at each slide latch location corresponding in size and spacing to the four spuds  84 . Each spud is inserted into its corresponding hole. The end of each spud is ultrasonically melted into the countersunk underside of its corresponding hole to form a headed fastener similar to a rivet. Also included as part of the unitary construction of body  26  is a recessed opening  85 , sides  86  and  87 , upper panel  88 , side notches  86   a  and  87   a , and recessed ramp  89 . Opening  85  includes a generally straight, inner abutment edge  85   a.    
     The slide member  27  fits within body  26  and the slide lip  28  is captured between the slide member  27  and the surface of the tray. The details of slide member  27  are illustrated in  FIGS. 31 and 32 . The details of slide lip  28  are illustrated in  FIG. 33 . As should be clear from the set of drawings, actuation of slide button  29  from a closed to open condition involves applying a slight downward force (“downward” being in the direction of the tray) with a pushing or sliding force in the direction of desired movement for slide lip  28 . When moving the slide member  27  from the open to closed condition, the slight downward force on slide button  29  is not required, only the sliding force, as will be explained hereinafter. 
     Referring to  FIGS. 31 and 32 , unitary slide member  27  includes an upper panel  92  and a lower panel  93  that are flexibly connected together at hinge end  94 . This construction allows upper panel  92  to flex downwardly in the direction of lower panel  93  and then spring back due to the flexibility and spring characteristics provided by the panel-to-panel integral (unitary) connection via hinge end  94 . Upper panel  92  includes a raised portion  95  adjacent slide button  29 . Portion  95  has a ramp shape with its lower end adjacent slide button  29 . Lower panel  93  includes a pair of oppositely-disposed, outwardly-extending notch tabs  96  and  97 . Lower panel  93  also includes a recessed area  98  inside of three-sided lip  99 . Area  98  includes a generally square, raised portion  100 . 
     Referring to  FIG. 33 , slide lip  28  includes an upper panel  103 , outer end  104 , and slot-receiving tab  105 . Tab  105  includes an angled, inner edge  106 . Upper panel  103  defines a generally square opening  107 . While other opening shapes are permissible, opening  107  needs to be sized and shaped to receive raised portion  100  of slide member  27 . By using a square shape for these interfitting portions, alignment in the X and Y directions can be easily maintained and precisely controlled. By providing a close fit with minimal clearance between opening  107  and portion  100 , the movement of slide lip  28  is smooth and precise with no need to take up any noticeable slack before slide lip  28  movement begins in response to movement of the slide member  27 . 
     Now with continued reference to  FIGS. 21-28 , it will be appreciated how the specific shapes of the three parts of slide latch  24  fit and interfit with each other for the movement of slide lip  28  from the closed condition of  FIGS. 21-24  to the open condition of  FIGS. 25-28  and back. In the starting closed condition, the raised portion  100  is received in square opening  107  such that sliding movement of slide member  27  translates into sliding movement of slide lip  28 . The higher end of raised portion  95  is in abutment against inner edge  85   a . Until this abutment is eliminated, the slide lip  28  does not change position and remains in its corresponding and cooperating tray slot  30 . In this position, the closing lid  21  or  80  is securely retained to the tray so as to complete and provide a closed case. 
     When the slide button  29  is pushed downwardly, the described abutment is relieved and the slide member  27  is able to move outwardly, i.e., away from the edge of the tray. The downward force applied to slide button  29  only has to be maintained until the higher end of portion  95  clears edge  85   a . Thereafter, portion  95  simply rides on the underside surface of upper panel  88  until the abutment face of recessed ramp  89  is contacted. This sets the desired open condition and the amount of movement between the two described abutment positions draws the slide lip  28  out of its corresponding and cooperating slot  30  so that the closing lid can be lifted off of the corresponding tray. In terms of the referenced corresponding tray, if a plurality of trays are stacked together, this would be the uppermost tray in that stack. If only a single tray is provided, then of course the corresponding tray is that single tray. 
     In order to move from an open condition back to a closed condition, depressing slide button  29  by pushing downwardly on it is not a required step since there is no abutment to be disengaged when moving in the reverse direction. Instead, the only manual manipulation of slide button  29  that is required is sliding motion due to the various ramp angles and directions of incline. As would be expected, there will be a “snap” when upper panel  92  pops up as portion  95  returns to its position in recessed opening  85 . In order to avoid any risk of moving slide member  27  too far in either direction, notch tabs  96  and  97  slide in notches  86   a  and  87   a , respectively. The fixed length of each slide notch with closed ends provides a positive stop, in each direction, if needed. As currently designed, the “proper” movement of slide member  27  is such that the notch tabs do not contact the ends of the corresponding side notches  86   a  and  87   a.    
     While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.