Patent Publication Number: US-11377294-B1

Title: Packaging tray for rollable objects

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Application No. 62/524,817, filed Jun. 26, 2017, the contents of which are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND 
     Modern fulfillment centers, warehouses, and the like handle an enormous number of commercial products of various shapes and sizes. Products (that is, items) often are carried in totes on conveyors or other transport systems. Totes often use well-known means for identifying the product or products within the tote, which enables a system or process the items in the vast throughout required in a commercial fulfillment center and the like. 
     Because a conventional tote has sidewalls, totes can contain products or packages that are rollable. Rollable products or packages (that is, those having a curved surface that can roll or rock), referred to herein as “objects,” when not in a tote are difficult to handle on conveyors or other systems that move the products. In this regard, conveyor systems and other transport systems or packaging systems require accurate information about the location of a product to reliably handle the products, especially in an automated setting. Products that roll or rock out of position can be, of course, detrimental to the operation of the handling and packaging functions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a first embodiment tray; 
         FIG. 2  is an end view of the tray of  FIG. 1 ; 
         FIG. 3  a side view of the tray of  FIG. 1 ; 
         FIG. 4  is a schematic (not to scale) view of a die-cut flat sheet that is used to form the tray of  FIG. 1 ; and 
         FIG. 5  is the side view of the tray of  FIG. 3  shown with a rollable object engaged with the tray. 
     
    
    
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     In some modern fulfillment centers, warehouses, or courier service company facilities, and the like, products or packages move on either a continuous belt conveyor or on several, end-to-end short conveyors. In this regard, the products or packages (that is, the “objects”) can be carried directly on the belt without being housed in a tote. The objects can be singulated or otherwise spaced and moved on the conveyors or conveyor segments in several ways. 
     For example, end-to-end conveyors can be individually controlled by starting and stopping or controlling the conveyor speed. A sensor, such as a photoelectric sensor, can determine the location of the leading edge of the object, and the motor revolutions can be determined with an encoder such that the position of the package on the belt is accurately known. 
     But the position of the products can be uncertain when the object is capable of moving, such as rolling or rocking, on the belt. For example, where the object has a curved outer surface (such as when the object is a right angle cylinder), the object can roll or rock upon acceleration or deceleration of the belt after the object passes the photoelectric sensor. Upon rolling or rocking, the location of the object might not be known or the object might not be in its expected location. The uncertainty or inaccuracy of this location information can, in some circumstances, cause the object to fail to be picked up by a robot or other automated system or to be properly inducted into a downstream conveyor system. 
     Referring to  FIGS. 1 and 5 , an assembled V-tray or tray  10  is a unitary structure that is capable of restraining movement of a rollable object while the tray carries the object. The specification uses the term “rollable” to refer to products or packages that have a curved outer surface, such as but not limited to a right circular cylinder having a circular cross section as shown by object  12  in  FIG. 5 , that can roll or rock on at least one axis. The tray defines a first axis CL 1  that is parallel to the longitudinal axis of object  12  and a second axis CL 2  that is perpendicular to the first axis CL 1 . In the embodiments shown in the figures, axis CL 1  defines a longitudinal centerline and defines the longitudinal or lengthwise direction of the upstanding structures that retain object  12 , as explained more fully below. Preferably, tray  10  is symmetrical about first axis CL 1  and symmetrical about second axis CL 2 . Tray  10  can optionally be an insert that is inserted into an outer box for shipping. 
     Tray  10  includes a pair of upstanding structures  20   a  and  20   b  on opposing sides of first axis CL 1  and a base panel  30  from which upstanding structures  20   a  and  20   b  vertically extend. The references numerals are appended with an “a” and a “b” designation to refer to corresponding, paired structures that (preferably) are the same, but on opposing sides, and preferably mirror image. The present invention is not limited to symmetrical structures, however, as the letter designations are not intended to limit the scope of the present invention, but rather merely are for ease of describing only one embodiment. Moreover, the terms “side” and “end” are chosen merely for ease of description of one embodiment, and are not intended to limit the scope of the invention. Where convenient, the structures are referred to by reference numeral only, without the appended letter designation. 
     In the embodiment shown in the figures, each upstanding structure  20   a  and  20   b  is a triangular prism—that is, a three dimensional structures having a cross section in a plane perpendicular to first axis CL 1  that is a triangle. The prisms  20   a  and  20   b  extend from end to end of tray  10  so as to be co-extensive in length with base panel  30 . 
     The triangle of prism  20   a  includes and is formed by a first leg  21   a , a second leg  22   a , and a third leg  23   a  to form a first vertex  25   a  between first legs  21   a  and an outboard portion of base panel  30 , a second vertex  26   a  between first and second legs  21   a  and  22   a , and a third vertex  27   a  between second and third legs  22   a  and  23   a . On the opposing side, the triangle of prism  20   b  includes and is formed by a first leg  21   b , a second leg  22   b , and a third leg  23   b  to form a first vertex  25   b  between first legs  21   b  and an outboard portion of base panel  30 , a second vertex  26   b  between first and second legs  21   b  and  22   b , and a third vertex  27   b  between second and third legs  22   b  and  23   b.    
     Base panel  30  includes a base panel top surface  32  and an opposing base panel bottom surface  34 . Outboard portions  36   a  and  36   b , as best shown in  FIG. 2 , of base panel  30  extend end to end on opposing sides of first axis CL 1  and are defined as the portions of base panel  30  that extend under or are covered by upstanding structures  20   a  and  20   b . In the embodiment shown in the figures, the underside surface of third legs  23   a  and  23   b  are parallel to and in contact with the top side of base outboard portions  36   a  and  36   b . As explained more fully below, third legs  23   a  and  23   b  optionally have a means to affix them to outboard portions  36   a  and  36   b , respectively. For example, the third leg has a bottom surface that is adhered to an upper surface of the base panel, such as by an adhesive, double sided tape, or like means. In addition or alternatively, outboard portions  36   a  and  36   b  may have tabs that are inserted into corresponding apertures in first legs  23   a  and  23   b  (not shown in  FIGS. 1 and 2 ) to affix the legs to the base. 
     A contact surface  40   a  may be defined by the surface and/or line (parallel to first axis CL 1 ) defined by second vertex  26   a  and/or second leg  22   a . And a contact surface  40   b  may be defined by the surface and/or line (parallel to first axis CL 1 ) defined by second vertex  26   b  and second leg  22   b . Thus, when object  12  is in its retained position in tray  10 , as shown in  FIG. 5 , such that try  10  carries object  12 , the outer surface of object  12  engages (that is, contacts) surfaces  40   a  and  40   b . The specific portions of contact portions  40   a  and  40  that object  12  contacts will depend on the diameter of object  12  and, where applicable, its shape, and on the dimensions of tray  10 . In this regard, an object  12  having a smaller relative diameter than that shown in  FIG. 5  may contact second legs  22   a  and  22   b  and a portion of base panel  30 . For another example, if the object is oval in cross section (not shown in the figures), the object may contact the vertex  26  on one side, the second leg  22  on the other side, and also a portion of base panel  30 . If the object has a significantly larger relative diameter, it might contact only vertices  26   a  and  26   b . Other contact possibilities are contemplated. 
     In this regard, the term “contact surface” as used herein refers to the vertices  26   a  and  26   b  and second legs  22   a  and  22   b  to indicate the main structures that are configured to retain the object even if a particular object does not actually contact both surfaces. Thus, the present invention is not limited to structures or combinations for which contact is achieved at surfaces  22  and  26 , nor is the invention limited to structures or combinations that contact only surfaces  22  and  26 . Further, the present invention is not limited to a continuous contact along the length (that is the dimension parallel to first axis CL 1 ), nor are the contact surfaces required to be parallel to axis CL 1 , nor continuous, nor linear (that is, straight). For example, legs  21  and  22  and/or base  30  may include recesses into which object  12  can reside for enhanced retention. 
     The dimensions of the components of tray  10  can be chosen according to the particular intended functions or uses of the tray and the desired product size ranges and cross sectional shapes of the products.  FIG. 2  shows a particular embodiment of a tray  10  in which base panel  30  (including outboard portions  36   a  and  36   b ) has a width dimension W 1  of 5.0 inches and the uncovered portion of base panel  30  has a width dimension W 2  of 1.7 inches. The height H of each upstanding structure is approximately 1.3 inches. 
     The orientation of first leg  21  forms an included angle A 1  between first leg  21  and third leg  23 , which for purposes of defining the angles leg  23  is presumed to be horizontal, of 65 degrees. Angle A 2  between first and third legs  21  and  22  is 65 degrees. Angle A 3  between second and third legs  22  and  23  is 50 degrees. Preferably, the lengths L 1 , L 2 , and L 3  of the legs are chosen to achieve the angles A 1 , A 2 , and A 3 , widths W 1  and W 2 , and height H. All of the dimensions provided herein are illustrative, and the specific dimensions and angles may be chosen according to the particular parameter of the application, such as expected shape, dimensions, and variability of the object; speed, acceleration, and deceleration of the belt carrying the tray; and like parameters, as will be understood by persons familiar with packaging technology. 
     The materials forming tray  10  can include any sheet material, as described more fully below. For example, tray  10  may be formed of corrugated fiberboard, card stock, paperboard, or a plastic. 
     Preferably, in operation, object  12  is retained in tray  10  and is restrained from moving side-to-side (that is, in the direction of second axis CL 2 ) while tray  10  carries object  12 , either at rest or while moving, accelerating, and decelerating. Thus, the restraining function of tray  10  is useful when tray  10  is at rest and also when the base bottom surface  34  is on a conveyor for transferring object  12 . In some configurations, tray  10  will be oriented to travel parallel to first axis CL 1 , such that object  12  is prevented from transverse or sideways movement (that is, in the direction parallel to transverse axis CL 2 ) on the conveyor. This configuration is useful, for example, in conveyor configurations in which a first conveyor discharges objects onto a second conveyor that is perpendicular to the first conveyor. In other configurations, tray  10  and object  12  can are orientated to travel in a direction parallel to second axis CL 2 . 
     Preferably, the proximal and distal ends (that is, the outermost portions of tray  10  along first axis CL 1 ) are open such that the ends do not have upstanding structures relative to base panel  30 . In this regard, the ends enable objects  12  to be received between upstanding structures  20   a  and  20   b  without interference, although such structure or lack of structure is not required. 
     Referring to  FIG. 4 , a die cut sheet  50  is illustrated schematically and not to scale. Sheet  50  is the intermediate structure from which tray  10  is formed. Sheet  50  can be a corrugated fiberboard, card stock, paperboard, or a plastic. The phrases “corrugated fiberboard, card stock, paperboard” are intended broadly to encompass any sheet product that includes a paper component, either in a layer, mixture, or chemical composition. The term “plastic” is intended broadly to encompass any sheet material that includes a polymer, either as a layer, mixture, or chemical composition. The plastic sheet may, for a non-limiting example, be a rigid sheet. 
     Sheet  50  includes a base panel  70  and, extending outwardly in the direction parallel to axis CL 2 , a pair of opposing first side panels  61   a  and  61   b , a pair of second side panels  62   a  and  62   b , and a pair of third side panel  63   a  and  63   b . The first panels  61   a  and  61   b  are separated from base panel  70  by first scores  65   a  and  65   b . Second panels  62   a  and  62   b  are separated from first panels  61   a  and  61   b  by second scores  66   a  and  66   b . Third panels  63   a  and  63   b  are separated from second panels  62   a  and  62   b  by third scores  67   a  and  67   b . Scores  65 ,  66 , and  67  facilitate folding of the sheet  50 . The score can be a groove or a slice that is cut into or in another way formed part way through sheet  50 , or can be perforations through at least part of sheet  50 , or can be any other score means as will be understood by persons familiar with relevant packaging or box technology. 
     Accordingly, the preferred shape of sheet  50  is a rectangle such that the panels each preferably extend along the first axis CL 1  by a dimension L. Length L of sheet  50  is also the length of tray  10 , and for illustration can be four inches, six inches, or eight inches. Other lengths are contemplated. Together, the panels sum to dimension W 3  in the direction parallel to second axis CL 2 . Sheet  50  is generally planar, which term is used to refer to the generally flat nature of sheet  50 , even though sheet  50  may include surface imperfections on unevenness common in commercial products, raised or recessed portions, scores, cut-outs, curls, and the like. 
     To form tray  10  from sheet  50 , the panels  61   a ,  62   a , and  63   a  are folded such that the sheet  50  hinges at scores  65   a ,  66   a , and  67   a . Panel  61   a  thus forms leg  21   a . Panel  62   a  forms leg  22   a . Panel  63   a  forms leg  23   a . In this way, panels  61   a ,  62   a , and  63   a  are folded into a configuration that forms the triangle shape of first upstanding structure  20   a . Panels  61   b ,  62   b , and  63   b  likewise are folded to form upstanding structure  20   b.    
     Upon contact of the underside of panel  63   a  with the surface  72  of base panel  70  that forms underlying portion  36   a , in some embodiments, a means to affix leg  23   a  to panel  36   a  can stiffen or secure the shape upstanding portions  20  of tray  10 . As illustrated schematically in  FIG. 4 , an adhesive  84   a  (illustrated in dashed lines) can be applied to the underside of panel  63   a  which when folded contacts the upper side of panel  36   a . Thus, adhesive  84   a  can affix leg  23   a  to panel  36   a  by adhesion. An adhesive  86   a  can be applied to the portion of panel  70  that forms underlying portion  36   a  to adhere the leg to the base panel. Adhesives  84   a  and  86   a  can be placed at corresponding portions such that adhesive  84   a  contacts  86   a , adhesive  84   a  may be positioned such that is does not contact adhesive  86   a , or only one of either adhesive  84   a  or  86   a  may be employed in the embodiments using adhesives. The term “adhesive” or “adhere” is broadly intended to refer to any means for permanent or temporary bonding, including for example double sided tape, pressure sensitive materials, hot glue, and the like. 
     Further, the portion of panel  70  that forms underlying portion  36   a  may include a tab  80   a , which preferably is die cut into sheet  50  such that tab  80   a  can be folded upwardly out of the plane of sheet  50 . A corresponding slot or aperture  82   a  is formed into panel  63   a  such that when panel  63   a  is folded into position to form leg  23   a , tab  80   a  is inserted into aperture  82   a  to affix leg  23   a  and base panel  36   a  together. Likewise, a tab  80   b  and slot or aperture  82   b  has the same structure and function for leg  23   b  and base panel  36   b  as that described for tab  80   a . Employing means to secure the upstanding portions  20  to the base is optional, regardless whether by adhesive or structural tabs and the like, as the weight or object  12  alone may aid in retaining the shape of the upstanding portion in some configurations. 
     Alternatively, the side structures, such as each prism shape described herein, may be formed without a third leg (as identified by reference numerals  23   a  and  23   b ) or other structure that lies on or parallel to panel  70 . In this alternative (not shown in the figures), a tab extends from each opposing side of the sheet  50  (that is, from the sides defined by dimension L). Slots or apertures that correspond to the tabs are formed on panel  70 . In its assembled state, the tabs extend into or through the apertures to hold the side structure in its raised configuration, and thus adhesives such as adhesives  84  and  86  and internal tabs and apertures such as tabs  80  and apertures  82  are optional and in some embodiments may be eliminated. To form the alternative embodiment, the panel has only two scores, which when bent position the tabs can to engage the apertures. In a manual assembly process, an assembler&#39;s thumbs can push the tabs into or through the apertures to secure or lock the structure in place. 
     The present invention is not limited to the particular structures or embodiments described above. For just a few examples, the upstanding structures are not limited to a triangular cross sectional shape. For example, the inventors contemplate and the invention encompasses that a square, rectangle, or other polygonal or curved shape can be suitable depending on the particular parameters and goal of the tray. And the upstanding structures are not limited to the position or orientations explained herein. Further, the present invention is described using figures and text of merely one embodiment, which is intended merely to illustrate aspects of the inventive concepts. The present invention is not intended to be limited to the drawings and accompanying text, but rather it is intended that the scope of the invention be defined by the full breadth of the claims.