Abstract:
A tray has a containment space defined by a tray floor and a continuous peripheral ridge extending upwardly from the tray floor. The ridge has an inner sidewall extending inward and downward from an upper edge of the ridge and an outer sidewall extending downward from the upper edge of the ridge. Multiple trays are coupled together by a connector member having lobes that mate with the shell-like structure of the ridge, and provide additional strength to the peripheral ridge. The tray can be provided with a shell-like construction such that multiple trays can be stacked compactly one on top of the other.

Description:
FIELD OF INVENTION 
   The invention relates to a system of trays for containing and disposing of drips or spills. 
   BACKGROUND OF INVENTION 
   Drips and spills can originate from many industrial and domestic sources. The need to prevent or control these spills is dependent upon the type of fluid or material being lost, and the location where this loss occurs. 
   For example, environmentally hazardous materials such as fuels, lubricants, process chemicals or paint must be collected regardless of location. Less hazardous materials such as road salt, or mud and grime may only need to be collected if they are damaging to the floors or structure of a building. 
   In each particular case, the type of material may be the greatest factor, or the location may be the greatest factor in determining the best method of containment and disposal. The relative seriousness of each would also dictate whether immediate preventive actions are necessary or possible. 
   In many domestic or light industrial applications there are situations where a specifically conFig.d containment and handling system is needed. The ability to assemble a system from a selection of basic modules of various shapes and sizes will address this need. 
   The nature of the drip source or the common spill pattern will dictate what the arrangement of the drip trays should be. This may require that the trays be in a rectangular arrangement to protect a large area. This may also dictate an arrangement in end-to-end relation to allow containment of drips from a travelling source. Some situations require that the containment take place in several specific areas by individual containment structures. 
   These modular systems must possess the structural integrity necessary to withstand loads when in high traffic areas where constant foot traffic or wheeled traffic such as carts or vehicles will be encountered. 
   These modular shapes must also be easily removable for disposal purposes, or for temporary storage. The ability of the structure to conform to uneven surfaces would be of further benefit as many floor surfaces are not flat. 
   Drip trays of the prior art are arranged in rectangular grids and are secured together in this grid-like pattern by jaw-like members. These drip trays also have overlapping flanges, which provide the ability to capture all of the material that may fall within the affected areas. 
   This system would be effective, but appears to have some drawbacks. The structure of the grid pattern does not appear to allow continuous end-to-end arrangement, and the method of securing the trays together requires removal of the jaw-like member to accomplish removal. The edge structure also prevents the traverse of wheeled traffic in any direction. 
   A drip tray with a different structure would be more effective when used as an individual item, would allow for many more arrangement options that could fit in more varied applications. The ability to remove and store these trays could be facilitated as well. 
   The commercial features of the tray must also be considered in some detail. The ability to compactly arrange individual trays when in transit for retail purpose and for storage must be considered. 
   SUMMARY OF THE INVENTION 
   It is an objective of the invention to provide a tray adapted for use in a system of trays in which each tray is easily manageable while retaining the material that it contains for relocation or disposal, while being durable and resilient to the passage of traffic. 
   It is also an objective to provide for easy positioning and moving of a tray or group of trays. 
   The present invention consists of modular trays of differing sizes that can be used individually, or in multiples, to provide containment for spills and drips. Multiple numbers of these trays may be loosely arranged or coupled, to address specific needs. 
   The tray is molded of a polymer-type material which provides for a chemical and corrosion-resistant structure. It also provides semi-rigid mechanical characteristics that are important to the handling and positioning of the tray and its reaction to loads. 
   When in a coupled arrangement, it is possible that unintended accidental forces may be applied to a one of the trays of the arrangement. If sufficient forces are applied, the unique shape of the structural lobes and ridge sidewalls, in conjunction with the polymer material&#39;s mechanical properties, will allow the disengagement of the tray experiencing the force from adjacent trays without any resultant material failures. 
   The trays may be used individually to catch drips from smaller sources such as a leaky mechanical drive train component, a leaky plumbing fixture or an industrial process such as a conveyor belt intersection. The trays can be arranged in adjacent arrays to catch paint drips, chemical strippers or wash fluids under conveyor systems. 
   A primary use of the trays would be in domestic vehicle garages where they will be used to catch melt water, rain water, salt, mud and general road grime that is transported there by way of vehicle exteriors. 
   The trays in an array can be loosely coupled with connector members. The peripheral ridge of the tray will fit loosely over top of lobes on the connector member extending upward. The connector member can be fastened mechanically to one of the adjacent trays with screws or the like. 
   The connector member can be an integral molded component comprising lobes extending upward from a plate, thereby increasing the structural integrity of the peripheral ridge of the tray at chosen locations to support vehicle wheels passing over the peripheral ridge. The sloped outer sidewalls, and relatively low profile of the peripheral ridge allows vehicles to pass over without forcing the tray from its position. 
   A tray may be easily removed by means of a handle that can be used to grip the individual modules through aperture in the outer sidewall structure or similar perforations in the lobes of an attached connector member. The weight of each tray is such that an individual with average abilities may drag the combined weight of the tray and contents to a suitable location for surface disposal. 
   When environmentally hazardous materials must be disposed of there will be more appropriate disposal methods required. An aid to this is provided in the form of an absorbent pad that can be held in the tray by a spring wire retainer clip. Reusable materials may be utilized for this absorbent pad where liquids can be pressed into approved containers and disposed of separately. 
   Entry and exit of wheeled traffic may create waveforms in contained liquid, which can be prevented from overflowing the edges of the tray with the addition of a specifically designed baffle system. Methods of incorporating this feature may vary. A separate component consisting of a molded polymer structure, or fabricated rubber strips may be added as an option. 
   In one aspect, the invention provides a tray having a containment space defined by a tray floor and a continuous peripheral ridge extending upwardly from the tray floor. The ridge has an inner sidewall extending inward and downward from an upper edge of the ridge and an outer sidewall extending downward from the upper edge of the ridge. 
   The tray can be provided with a shell-like construction such that multiple trays can be stacked compactly one on top of the other. 
   In another aspect of the invention, multiple trays are coupled together by a connector member having lobes that mate with the shell-like structure of the ridge, and provide additional strength to the peripheral ridge. 

   
     DESCRIPTION OF DRAWINGS 
       FIG. 1A  is a perspective view of a tray of the invention; 
       FIG. 1B  is a perspective section view of the peripheral ridge of the tray; 
       FIG. 2A  is a perspective of the tray with a drag handle attached; 
       FIG. 2B  is an end section view of the peripheral ridge of the tray illustrating the angular arrangement of the inner and outer sidewalls that form the peripheral ridge; 
       FIG. 2C  is a schematic section view illustrating the stacking facilitated by the outward slope of the outer sidewall; 
       FIG. 2D  is a side section view of the peripheral ridge of the tray illustrating the mechanical geometry of the drag handle attachment; 
       FIG. 3  is a perspective view of a connector member; 
       FIG. 4A  is a section view of the connecting member of FIG.  3  through the lobes; 
       FIG. 4B  is a section view of the connecting member of  FIG. 3  adjacent to the lobes; 
       FIG. 5  illustrates assembly of a typical tray array; 
       FIG. 6A  is a plan view of a loose array of trays; 
       FIG. 6B  is a plan view of a coupled array of trays; 
       FIG. 6C  is a plan view of an angular coupled array of trays; 
       FIG. 7  is a plan view of an array of trays for a typical industrial application; 
       FIG. 8  is a perspective view showing the operation of a spring wire retainer for holding an absorbent pad in position; 
       FIG. 9  is an end view of a filler cap; 
       FIG. 10  is a schematic section view showing the filler cap in position between two adjacent trays in an array of trays; 
       FIG. 11  illustrates an alternate filler cap member. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     FIGS. 1A and 1B  show a tray  1  of the invention consisting of a tray floor  3  with an integral molded peripheral ridge  5  around the periphery. The sidewall structure incorporates an angled inner sidewall  10  and outer sidewall  20  intersecting at an upper edge  7  at the top. The cross-section of the ridge  5  can be described as an inverted V-shape. The nominally low ridge height and angled sidewalls  10 ,  20  allow wheel passages without the containment tray  1  being dislodged from its position. The intersecting angles ‘X’ and ‘Y’ that each sidewall  10 ,  20  forms with the vertical are not equal in this example. The angle ‘X’ formed with the outer sidewall plane is the minimum required to allow a plurality of trays  1  to be stacked prior to assembly, as shown in FIG.  2 C. The corresponding internal angle ‘Y’ is sufficient to provide enough open section to allow the engagement of a connector member  40  as in FIG.  5 . 
   The outer sidewall  20  is modified to allow the temporary attachment of handles for dragging, lifting or storage. Apertures  30  are made in the outer sidewall  20  for this purpose.  FIG. 2A  shows the insertion of a handle  33  with bent fork-like prongs  35 . As the handle  33  is rotated downward slightly the prongs will be locked into the perforated sidewall as in FIG.  2 D. The fulcrum point formed by the bend is forced against the floor or ground to provide a locking action. 
   A connector member  40  is shown in FIG.  3 . Shape is consisting of a plate  45  with integrally molded triangular lobes  41  extending upward from the plate  45 . These lobes  41  are arranged linearly with spaces between. The lobes  41  have closed endwalls  42  to provide structural integrity and strength sufficient to support vehicle wheels passing over the ridge  5 . The lobes  41  conform generally to the tray sidewalls  10 ,  20 , as can be seen in FIG.  10 . 
   Apertures  30  for drag handle connection, and apertures for hanging storage  31  are incorporated in the molded connector members. The fulcrum point, described above for the apertures  30  in the outer sidewall of the ridge  5  may be applied to the plate  45  of the connector member  40  to provide a locking action similar to that when the fulcrum point is the floor as in FIG.  2 D. 
     FIG. 4A  is a section view of the connector member  40 . The nominal separation distance ‘D’ between the two linear rows of lobes is such that the outer sidewalls  20  of a tray  1  fit loosely into the space provided. In this manner, the lobes  41  may provide support for the ridges  5  on two or more adjacent trays  1 . An inherent coupling action is also provided in conjunction with this arrangement. Any application of sufficient tensile loads, rotational forces or lifting forces, either individually or in combination will separate an unattached tray  1  from this arrangement. For example, the application of rotational forces, which result from movement of vehicle steering axles, will dislodge the affected tray from other trays in this arrangement without damage to the individual tray&#39;s structure. The trays  1  and outer sidewalls  20  are resilient and will flex to allow disengagement. 
     FIG. 5  illustrates the attachment of a connector member  40  to a ridge  5  of a tray  1  with screws  49  or like method. Alternative fasteners such as ribbed plastic pins will allow for much easier detachment when necessary. Similar attachments may be made to the opposite or adjacent ridges of this module. Note apertures  30 ,  31  in connector members are oriented to the outside of the tray  1 . 
     FIGS. 6A and 6B  illustrate typical vehicle storage applications.  FIG. 6A  shows a loose arrangement of trays with connector members  40  attached as necessary to support vehicle traffic in direction T.  FIG. 6B  shows a coupled array of trays  1  for a larger vehicle, which may possess more capability for carrying moisture or contaminants. 
   Note that trays  1  that are in coupled arrays as shown will utilize one connector member  40  for support and inherent coupling purposes.  FIG. 6C  shows coupled arrangement of a non-rectangular tray  1 A to adjacent rectangular trays  1 . In this example the intersecting angle is 45 degrees. Alternative shapes may be produced with a variety of angles determined by configuration requirements. 
     FIG. 7  is a plan view of typical configuration for industrial purposes. Machine center chips and scarf, and accompanying cutting fluid, are elevated by chip conveyors  52  onto a low conveyor  55  for transport to a central collection location such as container  54  for removal. Any of these materials that adhere to the conveyor belt may fall to the floor surface on the return pass (lower surface). 
   Most drilling fluids are considered hazardous, and the chips and scarf are often difficult to sweep. It would be much more advantageous to collect them in the tray array shown. Note the short ‘square’ tray  50  used in the confined space between VMC  1  and VMC  2 . 
     FIG. 8  is a perspective of a module  1  with an absorbent pad  65  covering a substantial portion of the tray floor  3 , and maintained in position by a formed spring wire clip  66 . 
     FIGS. 9 and 10  illustrate a filler cap  70  adapted to engage adjacent trays  1  and to cover the gap  72  between the upper edges  7  of the peripheral ridges  5  of the adjacent trays  1 . The filler cap  70  comprises a cap member  75  extending laterally beyond the upper edge  7  of the peripheral ridge  5  of each adjacent tray  1 , as illustrated in  FIG. 10. A  lock member  76  extends downward from the center of the cap member  75 . A pair of resilient legs  77  extend downward from the bottom end of the lock member  76 . The legs  77  are separated by an empty space such that same may flex toward each other. Each leg  77  comprises an outward extending tab  78  adapted to engage the bottom edge  22  of outer sidewalls  20  of an adjacent tray  1 . A resilient centering member  79  extends outward on each side of a midpoint of the lock member  76  and bears against the outer sidewall  20  of each adjacent tray  1 . 
   Alternatively, as illustrated in  FIG. 11 , the legs can be omitted and the bottom end of the lock member  76  could comprise an outwardly extending tabs  78  on each side that push against the bottom edge  22  of the outer sidewalls  20  and cause them to flex such that the tabs move down and under the outer edge  22 , thereby engaging same and securing the filler cap  70  in place. 
   The trays and connector members are arranged as desired, and as illustrated, the connector member  40  is attached to one of the trays with a screw  49  or the like. The lock member  76  of the filler cap  70  is then pushed down into the gap  72  between trays. The resilient legs  77  are squeezed together until the tabs  78  reach the bottom edges  22  of the outside sidewalls  20 , whereupon the legs  77  spring out so that the tabs  78  are under the bottom edges  22  of the outer sidewalls  20 . The centering members  79  hold the lock member  76  substantially centered in the gap  72  to properly position the cap member  75  so that it extends over the upper edges  7  of the ridge  5  on each tray  1 . 
   The filler cap  70  substantially prevents drips from falling into the gap  72 , and instead directs such drips into the adjacent trays  1 . The filler cap  70  is removed by an upward force applied thereto. The illustrated filler cap also serves to lock trays together such movement of one tray relative to another is inhibited. 
   The described invention provides a means of collecting materials that are leaking or spilling from various sources. The modular design allows for extensive configurations in a variety of applications, particularly in areas where wheeled traffic is encountered or industrial processes exist. 
   Persons skilled in the art will be able to make modifications to the illustrated embodiments without departing from the spirit and scope of the invention. As an example, the adjacent edges of each modular tray may not necessarily be in a right angle relationship to each other. There may be a desire to create module versions with edges that vary by 30 degrees, 45 degrees or other values, from the usual 90 degree relationship that forms a typical ‘corner’.