Patent Publication Number: US-9902523-B2

Title: Bakery tray

Description:
This application is a divisional of U.S. Ser. No. 13/359,542, now U.S. Pat. No. 8,763,809, which claims priority to U.S. Provisional Application Ser. Nos. 61/437,326, filed Jan. 28, 2011, 61/480,180, filed Apr. 28, 2011 and 61/566,510, filed Dec. 2, 2011. 
    
    
     BACKGROUND 
     Bakery trays typically include a base from which front, rear and side walls extend upward. The side walls may include feet that are arranged relative to recesses at upper edges of the side walls such that the tray can stack with an identical tray at a first orientation and nest (or stack at a different height) with the identical tray at a second orientation, where the second orientation is 180° relative to the first orientation. 
     When many of these trays are stacked or nested, a substantial portion of the weight from each tray and the trays above it is transferred to the tray below via the feet. However, for the bottom tray on the floor, the feet may not contact the floor. Rather, the bottom tray is supported on drag rails, which are inward of the feet. Thus, the weight of all the trays above the bottom tray bears on the bottom tray at points outward of the drag rails, which may cause the side walls of the bottom tray to twist outward. 
     SUMMARY 
     A tray having one feature disclosed herein includes a base and a plurality of walls extending upward from the base. A first wall of the plurality of walls includes a projection outward from the first wall. The projection is aligned with an upper edge of the first wall, such that the projection is outward of a portion of the upper edge of the first wall. In this manner, the projection of an identical upper tray stacked on the tray would interlock with the upper edge of the first wall to resist outward deflection of the upper edge of the first wall of the tray. 
     In one embodiment disclosed herein, the projection has a T-shaped cross-section, complementary to a T-shaped recess in the upper edge of the first wall. 
     A tray having another feature disclosed herein includes a base and a plurality of walls extending upward from the base. A platform extends inwardly from at least one of the walls. The platform can be used to support smaller trays stacked thereon. For example, trays that are approximately half the size of the tray can be supported on three of the walls and the platform. In the embodiment disclosed herein as one example, platforms extend inwardly from an opposing pair of the walls to support the half-size trays. 
     In a tray having another feature disclosed herein, a base includes front and rear walls extending upward from front and rear edges of the base. Side walls extend upward from side edges of the base. Each of the side walls includes at least one interlocking recess for receiving automated handling equipment for supporting the tray. 
     In one specific example disclosed herein, each interlocking recess is defined by a curved upper wall protruding outwardly from the side wall. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of tray according to a first embodiment. 
         FIGS. 2A and 2B  are side views of the tray. 
         FIG. 3  is a front view of the tray. 
         FIG. 4  is bottom perspective view of the tray. 
         FIG. 5  is a top view of the tray. 
         FIG. 6  is a perspective view of the tray with an identical tray stacked thereon in a low stack position. 
         FIG. 7  is a side view of the trays of  FIG. 6 . 
         FIG. 8  is a perspective view of the trays of  FIG. 6  in a high stacked position. 
         FIG. 9  is a side view of the trays of  FIG. 8 . 
         FIG. 10  is a perspective view of the tray with an identical tray being slide-stacked onto the tray. 
         FIG. 11  is an enlarged front view a portion of the trays of  FIG. 10 . 
         FIG. 12  is a perspective view of the tray stacked onto smaller prior art trays and having two prior art trays stacked thereon. 
         FIG. 13  is a front view of the trays of  FIG. 12 . 
         FIG. 14  is a side view of the trays of  FIG. 12 . 
         FIG. 15  shows the trays of  FIG. 12  with one of the upper trays removed. 
         FIG. 16  is an enlarged perspective view of one of the platforms supporting the prior art tray. 
         FIG. 17  is a cut-away view through the platform of  FIG. 16 . 
         FIG. 18  is an enlarged view of the platform of  FIG. 17 . 
         FIG. 19  is a perspective view of a halved tray (for purpose of illustration) stacked on the prior art tray. 
         FIG. 20  is an enlarged view of a portion of  FIG. 19 . 
         FIG. 21  is another enlarged view of a portion of  FIG. 19 . 
         FIG. 22  is a bottom perspective view of a portion of the base of the tray. 
         FIG. 23  is a perspective view of one side wall of the tray. 
         FIG. 24  shows the prior art tray in one orientation stacked on the side wall of  FIG. 23 . 
         FIG. 25  shows the prior art tray in the other orientation stacked on the side wall of  FIG. 23 . 
         FIG. 26  is a perspective view of the other side wall of the tray. 
         FIG. 27  shows the prior art tray stacked on the side wall of  FIG. 26  in one orientation. 
         FIG. 28  shows the prior art tray stacked on the side wall of  FIG. 26  in the other orientation. 
         FIG. 29  is a perspective view of one side wall of the prior art tray. 
         FIG. 30  is a perspective view of the other side wall of the prior art tray. 
         FIG. 31  shows one side wall of the tray stacked on one of the side walls of the prior art tray. 
         FIG. 32  shows the tray stacked on the other side wall of the prior art tray. 
         FIG. 33  shows the other side wall of the tray stacked on one of the side walls of the prior art tray. 
         FIG. 34  shows the other side walls of the tray stacked on the other side wall of the prior art tray. 
         FIG. 35  is a perspective view of one side wall of the tray having a portion of automated handling equipment engaged therewith. 
         FIG. 36  shows the side wall of  FIG. 35  with the automated handling equipment disengaged therefrom. 
         FIG. 37  is a front view of the tray and the automated handling equipment engaged therewith. 
         FIG. 38  is a front view of the tray with the automated handling equipment disengaged therefrom. 
         FIG. 39  is a perspective view of a bakery tray according to a second embodiment. 
         FIG. 40  is an interior perspective view of one side wall of the tray of  FIG. 39 . 
         FIG. 41  is an exterior perspective view of one of the side walls of the tray of  FIG. 39 . 
         FIG. 42  is a bottom perspective view of the side wall of  FIG. 41 . 
         FIG. 43  shows the tray of  FIG. 39  with an identical tray stacked thereon in the high stacked position. 
         FIG. 44  is a section view through the trays of  FIG. 43 . 
         FIG. 45  is a perspective view of the trays of  FIG. 43  in the low stacked position. 
         FIG. 46  is a section view through the trays of  FIG. 45 . 
         FIG. 47  is a perspective view of the trays of the  FIG. 45  with the upper tray being lifted at one end. 
         FIG. 48  is a section view through the trays of  FIG. 47 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A bakery tray  10  according to one embodiment of the present invention 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 tray  10 , and side walls  15 ,  16  extending upwardly from side edges of the base  12 . The side walls  15 ,  16  include handles  18  formed therein. Each of the front and rear walls  14  includes a pair of handles  20  formed therein. Each of the front and rear walls  14  includes a platform  22  projecting inwardly adjacent an upper edge thereof and centered between the handles  20 . The platform  22  is generally hollow with openings  58  to the exterior of the tray  10  between ribs  60 . 
     Each of the side walls  15 ,  16  includes a pair of interlocking recesses  24  for interlocking with automated handling equipment. Each side walls  15 ,  16  further includes a rear foot  26 , front foot  28 , and center projection  30  projecting downwardly. The front foot  28  is adjacent the front edge of the tray  10  while the rear foot  26  is spaced away from the rear edge of the tray  10 . An upper edge of each side wall  15 ,  16  includes a rear recess  32  aligned with the rear foot  26 , a front recess  34  aligned with the front foot  28  and a center recess  36  aligned with the center projection  30 . An inner rail  38  extends across portions of the side walls  15 ,  16 . The front and rear walls  14  include a double-walled lip portion  40  that projects outwardly relative to a lower portion of the front and rear walls  14 . The upper edge of the front and rear walls  14  each include a raised central portion  44  adjacent the platform, a recessed portion  42  between the raised central portion  44  and each side wall  15 ,  16 , and an outer raised portion  45  adjacent each side wall  15 ,  16 . 
       FIGS. 2A and 2B  show the two sides of the tray  10 .  FIG. 2A  shows the same side wall  16  as  FIG. 1 .  FIG. 2B  shows the opposite side wall  15 . As shown in  FIG. 2A , on side wall  16 , the feet  26 ,  28  are spaced further outward (toward front and rear walls  14 ), while in  FIG. 2B , on side wall  15 , the feet  26 ,  28  are spaced further inward (away from front and rear walls  14 ). This is one way of providing stacking at a high stack position in one orientation and at a low stack position (or alternatively, nesting) in another (180 degree) orientation. 
       FIG. 3  is a front view of the tray  10 . 
       FIG. 4  is a bottom perspective view of the tray  10 . The base  12  includes a upper, planar panel portion  90  with a plurality of cross-ribs  92  projecting downward therefrom, including a peripheral rib  94  extending along most of the periphery of the front and rear walls  14 . Each peripheral rib  94  includes a recessed portion  96 , where the peripheral rib  94  juts inwardly to expose a portion  98  of the planar panel portion  90 . The exposed portion  98  of the upper planar portion  90  is aligned with the platform  22  ( FIG. 1 ). As a result, when one tray  10  is stacked on another tray  10 , the platforms  22  of the lower tray  10  will be received within the recessed portions  96  of the peripheral ribs  94  of the upper tray  10  and the ribs  92 ,  94  will not impact the platforms  22  and prevent proper stacking of the trays  10 . Drag rails  100  extend downward from the base  12  inward of each side wall  15 ,  16 . The drag rails  100  may be double-walled drag rails  100  with cross-ribs, as shown. The bottom surface of the feet  26 ,  28  on the side wall  15  each include a central recess  27 , while the feet  26 ,  28  on the side wall  16  each include a lateral recess  29 , such that the lateral recesses  29  are open laterally facing one another. 
       FIG. 4  also shows the interlocking recesses  24 . Each side wall  15 ,  16  includes a plurality of ribs  66  extending outwardly of a planar wall portion. Ribs  68  partially define the interlocking recess  24 . The ribs  68  form an upper curved wall and two generally vertical walls. A plurality of vertical ribs  72  extend downward from the upper curved wall to increase the strength and rigidity of the upper curved wall and to provide more gripping with the automated handling equipment. 
       FIG. 5  is a top view of the tray  10 . 
       FIGS. 6-7  show the tray  10  with a similar tray  10 ′ stacked thereon in a low stack position, i.e., in a similar orientation with the front feet  28 ′ received in the front recesses  34  and the rear feet  26 ′ received in the rear recesses  32 . The center projections  30 ′ are received in the center recesses  36 . 
     In  FIGS. 8-9 , the upper tray  10 ′ is rotated 180° and is stacked on the lower tray  10  in a high stack position, i.e., with the rear feet  26 ′ stacked on the upper edge of the side walls  16  and the front feet  28 ′ stacked on the upper edge of the side walls  16 , not received in the recesses  32 ,  34 . In the high stack position, larger goods or more layers of goods can be placed in the lower tray  10 . 
       FIGS. 10-11  illustrate the upper tray  10 ′ as it is being slide-stacked onto the lower tray  10 . Referring to  FIG. 11 , the upper edge of the front and rear walls  14  (front and rear walls  14  are symmetric about longitudinal and lateral axes in this embodiment) is shown in more detail. The upper edge of the front and rear walls  14  each includes the recessed portion  42  and an outer raised portion  45 . A notch  102  is formed in the outer raised portion  45  to accommodate the drag rail  100 ′ of the upper tray  10 ′. The feet  26 ′ of the upper tray  10 ′ rest on the inner rail  38  of the lower tray  10  and an upper surface  105  of the side wall  16 . A downward projection from the central projection  30 ′ of the upper tray  10 ′ extends into an outer notch  104  in the upper edge of the bottom tray  10 . An outer rail  106  projects upwardly from the side wall  16  outward of the upper tray  10 ′. 
     As shown in  FIG. 12 , the tray  10  can support thereon and be supported on two prior art trays  110  that are approximately half the size of the tray  10 . The prior art tray  110  includes a base  112 , front and rear walls  114  and side walls  116 . The prior art tray  110  is symmetric about the long axis, i.e. the side walls  116  are mirror images of one another. The front and rear walls  114  each include a plurality of vertical ribs  117  on an exterior surface thereof. The lower ends of the ribs  117  are aligned along an arc and therefore are not sufficient for stably supporting the prior art tray  110  on the front and rear walls  14  of the tray  10 . Thus, the front and rear walls  114  of the prior art tray  110  are also supported on the platforms  22 . 
     The prior art tray  110  includes rear support columns  118  having three castellations  120  on an upper support surface thereof. Front support columns  122  each have a single castellation  124  on an upper support surface thereof. 
     As shown in  FIG. 13 , the vertical ribs  117  of the prior art trays  110  align with the recessed portion  42  of the upper edge of the front and rear walls  14 . 
     Referring to  FIG. 14 , the feet  26  of the tray  10  contact the upper surface of the rear support columns  118  rearward of the castellations  120 . The feet  28  contact the upper surface of the front support columns  120  rearward of the castellation  124 . 
       FIGS. 15-17  show the trays  10 ,  110  of  FIG. 12  with one upper prior art tray  110  removed.  FIG. 16  is an enlarged view of one of the platforms  22  (the other is identical) supporting the prior art tray  110 . The platform  22  extends inwardly from an inner surface of each front and rear wall  14 . The platform  22  includes a central support surface  46  spaced away from outer support surfaces  48 . A ridge  50  projects upwardly from an inner edge of the central support surface  46 . Ridges  52  project upwardly from inner edges of the outer support surfaces  48 . Lower surfaces  54  are between each outer support surface  48  and the central support surface  46 . A rib  113  extending downwardly from the base  112  of the prior art tray  110  is supported on the lower surface  54  of the platform  22 . 
       FIG. 17  is a cutaway view through the platform  22  of  FIG. 16 .  FIG. 18  is an enlarged view of the platform  22  of  FIG. 17 . The platform  22  is generally hollow with openings  58  to the exterior of the tray  10  adjacent ribs  60 . 
       FIGS. 19-21  show a halved tray  10  (for purpose of illustration) stacked on the prior art tray  110 . Referring to  FIG. 20 , the base  12  of the tray  10  can be viewed as an upper, planar panel portion  90  from which a plurality of cross-ribs  92  extend downward. The recessed portion  96  of the peripheral rib  94  is supported on the upper support surface of the front column portion  122  inward of the single castellation  124 . Referring to  FIG. 21 , the cross-ribs  92  of the base  12 , are supported on the rear column portion  118  between the castellations  120 .  FIG. 22  is a bottom perspective view of the cross-ribs  92  and peripheral rib  94 , showing the arrangement to accommodate the castellations  120 ,  124  ( FIGS. 20-21 ). 
       FIGS. 23-25  together illustrate the alignment of the prior art tray  110  on the side wall  16  of the tray  10 .  FIG. 23  shows the side wall  16 . The rear foot  26  and front foot  28  are each outward of a window  128 , which is outward of the interlocking recess  24 . The rear recess  32  and front recess  34  are therefore also aligned outward of the windows  128 . 
     Referring to  FIG. 24 , in one orientation, the rear foot  130  of the prior art tray  110  is supported on the side wall  16  outward of the recess  32 , while the front foot  132  of the prior art tray is supported on the side wall  16  inward of the recess  34 . 
     Referring to  FIG. 25 , in the other orientation, the rear foot  130  is supported outward of the recess  34 , while the front foot  132  is supported inward of the recess  32 . 
       FIGS. 26-29  illustrate the alignment of the prior art tray  110  on the side wall  15  of the tray  10 .  FIG. 26  shows the side wall  15 . The rear foot  26  and front foot  28  are each inward of a window  128  and immediately adjacent the interlocking recess  24 . The rear recess  32  and front recess  34  are therefore also aligned inward of the windows  128 .  FIG. 27  shows one orientation of the prior art tray  110 , in which the rear foot  130  of the prior art tray  110  is supported on the side wall  16  outward of the recess  34 , while the front foot  132  of the prior art tray is supported on the side wall  16  outward of the recess  32 . Referring to  FIG. 28 , in the other orientation, the rear foot  130  is supported outward of the recess  32 , while the front foot  132  is supported inward of the recess  34 . 
       FIGS. 29 and 30  are upper perspective views of the side walls  116  of the prior art tray  110 .  FIGS. 31 and 32  show the side wall  15  of the tray  10  stacking on the side walls  116  of the prior art tray  110 . In  FIG. 31 , the front foot  28  is stacked on the side wall  116 , while the rear foot  26  is stacked on the rear support column  118 . One of the castellations  120  is received in the central recess  27  ( FIG. 4 ) of the rear foot  26 , adjacent the drag rail  100 . On the other side wall  116 , shown in  FIG. 32 , the rear foot  26  is stacked on the side wall  116 , while the front foot  28  is stacked on the rear support column  118 , with one of the castellations  120  received in the central recess  27  ( FIG. 4 ) of the front foot  28 , adjacent the drag rail  100 . 
       FIGS. 33 and 34  show the side wall  16  of the tray  10  stacking on the side walls  116  of the prior art tray  110 . In  FIG. 33 , the front foot  28  is stacked on the rear support column  118 , with one of the castellations  120  received in the lateral recess  29  ( FIG. 4 ) of the front foot  28 , adjacent the drag rail  100 . The rear foot  26  is stacked on the front support column  122 . On the other side wall  116 , shown in  FIG. 34 , the rear foot  26  is stacked on the rear support column  118 , with one of the castellations  120  received in the lateral recess  29  ( FIG. 4 ) of the rear foot  26 , adjacent the drag rail  100 . The front foot  28  is stacked on the front support column  122 . 
     Automated handling equipment may include a lifting and pulling device, such as the device  80  shown in  FIGS. 35-38 . The device  80  includes a center bar  82  having hinge pins  84  projecting from each axial end. Arms  86  extend downward from the center bar  82 . A projection  88  is formed at the outer end of each arm  86 . As shown in  FIGS. 37 and 38 , the device  80  can be used to engage the interlocking recesses  24  in either end of the tray  10 . The projection  88  at the end of each arm  86  provides some self-alignment between the device  80  and the tray  10 . The device  80  can lift and pull the tray  10 . 
       FIG. 39  is a perspective view of a bakery tray  210  according to a second embodiment. The bakery tray  210  is identical to the tray  20  of the first embodiment except as otherwise described below or as 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 tray  210 , and side walls  215 ,  216  extending upwardly from side edges of the base  212 . The side walls  215 ,  216  include handles  218  formed therein. Each of the front and rear walls  214  includes a platform  222  projecting inwardly adjacent an upper edge thereof and centered between the handles  220 . 
     Each of the side walls  215 ,  216  includes a pair of interlocking recesses  224  for interlocking with automated handling equipment. Each side walls  215 ,  216  further includes a rear foot  226 , front foot  228 , and center projection  230  projecting downwardly. Recesses in the upper edge of the side walls  215 ,  216  provide for different stacking heights; however, in this embodiment, the recesses for the high stacking position are positioned directly above the feet  226 ,  228  so that load can transfer directly from foot to foot in the high stacking position (in the low stacking position, there are many other contact areas between the upper tray and the lower tray in addition to the feet in the low-stacking recesses). 
     An upper edge of each side wall  215 ,  216  includes a center recess  236  above the handles  218  and aligned with the center projection  230 . 
     The center recess  236  is shown more clearly in  FIG. 40 . The center recess  236  is T-shaped including a large portion  237  and a narrow portion  239 , as defined by two wall portions  241 . 
     The center projection  230  is shown in more detail in  FIG. 41 . The center projection  230  is also T-shaped, having a single-wall thickness base rib  273  extending outward from the side wall  216  (the projection side wall  215  can be identical) to outer cross portion  274  generally parallel to the side wall  216 . Outer cross portion  274  includes a pair of vertical ribs  275  each having a tapered, narrow portion  276  above their bottom edges and above the bottom edge of the outer cross portion  274 . The narrow portions  276  are preferably curved, concave portions. A bottom horizontal rib  277  extends across the bottom of the vertical ribs  275  defining the bottom of the cross portion  274 . 
     A bottom view of the tray  210  is shown in  FIG. 42 , where the center projection  230  is also shown. 
     In  FIG. 43 , the tray  210  is shown with an identical tray  210  stacked thereon in the high stack position. The center projection  230  of the upper tray  210  is partially received in the center recess  236  of the lower tray  210 . The interlocking T-shapes of the center projection  230  and center recess  236  prevent the side walls  215 ,  216  of the lower tray  210  from bowing outward under the weight of the tray  210  and numerous other trays  210  stacked in turn thereon, which may each be loaded with goods. As shown in  FIG. 44 , the base rib  273  of the center projection  230  is received between the wall portions  241  of the center recess  236 , thereby capturing the cross portion  274  of the center projection  230  of the upper tray  210 , thereby preventing the side wall of the lower tray  210  from bowing outward. 
     In  FIGS. 45 and 46 , the trays  210  are in the low stacked position. The center projection  230  of the upper tray  210  is received fully within the center recess  236  of the lower tray  210 . 
     If the upper tray  210  is lifted at the opposite side, as shown in  FIGS. 47 and 48 , this pivots the center projection  230  within the center recess  236 . The narrow portions  276  of the vertical ribs  275  accommodate and receive the front edge of the side wall as the upper tray  210  is pivoted. Thus, the center projection  230  reinforces the side wall of the lower tray  210  during stacking, but also permits the upper tray  210  to pivot when stacked. 
     In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.