Patent Application
20240208688
Embodiments relate to a bakery tray, such as for storing, displaying, and/or transporting baked goods.
Bakery trays are commonly used to store, transport, and display a variety of baked goods. Such trays are typically made of metals like stainless steel or aluminum formed in a grid or mesh pattern of wires. While this structure allows for air circulation and visibility of the tray contents, sharp metal edges at joint areas of the mesh can result in cuts, scrapes, or other injuries during handling. Convention metal wire bakery trays may also be prone to rust or galvanized flaking, which could cause contamination of the baked goods stored therein. Metal trays may also be costly, heavy, and difficult to clean.
In one or more embodiments, a bakery tray includes a base including a top surface and a bottom surface, the top surface including a plurality of nesting tabs extending upwardly therefrom. A wall structure extends upwardly from a periphery of the base and includes an inner surface and an outer surface. The wall structure includes an upper rim having a uniform height above the base, the wall structure having a mesh configuration. The base and the wall structure are integrally formed from a plastic material, and the plurality of nesting tabs are configured to support another bakery tray nested within the bakery tray.
In one or more embodiments, the plurality of nesting tabs includes central tabs which are spaced along a central transverse axis of the base. In one or more embodiments, the plurality of nesting tabs includes edge tabs projecting upwardly from the base at each corner of the bakery tray and at each end of the central transverse axis. In one or more embodiments, the plurality of nesting tabs each have a height of between about 0.35 to about 0.4 inches above the top surface of the base.
In one or more embodiments, a height of the wall structure from the base to the upper rim is between about 2.5 inches and about 3 inches. In one or more embodiments, the mesh configuration of the wall structure includes longitudinal and transverse struts which define openings, wherein each opening has an area of approximately 1 in2. In one or more embodiments, the wall structure flares outwardly from the base such that a perimeter of the upper rim is larger than a perimeter of the base. In one or more embodiments, the top surface, the bottom surface, the inner surface, and the outer surface each have a radiused configuration. In one or more embodiments, the inner surface of the wall structure is rounded adjacent to corners of the bakery tray.
In one or more embodiments, a bakery tray includes a generally rectangular base including a top surface and a bottom surface, the top surface including a plurality of nesting tabs extending upwardly therefrom including central tabs projecting upwardly along a central transverse axis of the base, and edge tabs projecting upwardly from the base at each corner of the bakery tray and at each end of the central transverse axis. A wall structure extends upwardly from a periphery of the base and includes an inner surface and an outer surface, the wall structure including an upper rim having a uniform height above the base. The wall structure flares outwardly from the base such that a perimeter of the upper rim is larger than a perimeter of the base, the wall structure having a mesh configuration including longitudinal and transverse struts which define openings The base and the wall structure are integrally formed from a plastic material, and the plurality of nesting tabs are configured to support another bakery tray nested within the bakery tray.
In one or more embodiments, a system of nesting bakery trays includes a first bakery tray including a first base including a top surface, the top surface including a plurality of nesting tabs extending upwardly therefrom, and a first wall structure extending upwardly from a periphery of the first base, the first wall structure including a first upper rim having a uniform height above the first base, the first wall structure having a mesh configuration, the first base and first the wall structure integrally formed from a plastic material. The system further includes a second bakery tray including a second base including a bottom surface, and a second wall structure extending upwardly from a periphery of the second base, the second wall structure including a second upper rim having a uniform height above the second base, the second wall structure having a mesh configuration, the second base and the second wall structure integrally formed from a plastic material. The second bakery tray is configured to be nested within the first bakery tray with the plurality of nesting tabs supporting the bottom surface of the second base such that the second upper rim of the second bakery tray is disposed above the first upper rim of the first bakery tray when nested.
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
It is understood that directional terms as noted herein (e.g., upper, lower, top, bottom, vertical, horizontal, downwardly, upwardly, etc.) simply refer to the orientation of various elements as illustrated in the accompanying figures and the manner in which elements may be oriented relative to each other. Such terms are provided for context and understanding of the embodiments disclosed herein and are not intended to be limiting.
With reference first to
In the embodiments disclosed herein, the bakery tray 100 is constructed (e.g. injection-molded) from a plastic material such that it is durable, washable, reusable, and recyclable, such that the bakery tray 100 helps create a safer, lighter weight, more cost-effective, and sustainable baked goods supply chain. Plastic trays are lighter than metal trays, which can be advantageous for ease of handling, transportation, and reducing the overall weight of bakery displays or storage. Plastic trays may also have a lower up-front cost compared with metal trays, and plastic trays have smooth surfaces that are easy to clean. The bakery tray 100 disclosed herein is easily recyclable at the end of its useful life cycle and, unlike conventional metal wire bakery trays, does not corrode and is 100% rust-free and galvanized flake-free, thus preventing the contamination of baked goods disposed therein. Also unlike conventional metal wire bakery trays, the plastic construction of the bakery tray 100 prevents injuries due to cuts, scrapes, or puncture wounds during handling. Still further, reusable plastic offers a lower carbon footprint and a higher sustainability score than conventional metal alternatives.
In one or more embodiments, the bakery tray 100 is constructed from 100% virgin or recycled plastic resin or resin blend such as, but not limited to, HDPE (high density polyethylene) or PP (polypropylene) resin. The bakery tray 100 is composed of FDA-approved resins, colors, and additives, and may include FDA-approved color/coding options. Advantageously, the bakery tray 100 can be manufactured in a wide range of colors, allowing for customization or branding. In one non-limiting example, the bakery tray 100 may have an operational temperature range of approximately −10° F. to 165° F.
With continuing reference to
As shown, in one or more embodiments, the base 102 and the wall structure 104 have a perforated, mesh, grid or lattice configuration of longitudinal and transverse struts 110. In one non-limiting example, the longitudinal and transverse struts 110 define openings 112 with dimensions of approximately 1 inch×1 inch (1 in2) in area, although the openings 112 are not limited to this size or shape. In one or more embodiments, the size of the openings 112 may be optimized based on the following factors: maximizing strength, minimizing weight, and minimizing surface area for water collection. The mesh configuration of the base 102 and the wall structure 104 advantageously provides a lightweight bakery tray 100, requires less material for construction and thus is cost effective, allows any unwanted liquids to drain through the base 102 and the wall structure 104 such that the bakery tray 100 may be easily cleaned and dried, and facilitates air flow and cooling.
The base 102 includes a top surface 114 and an opposed bottom surface 116, and the wall structure 104 includes an inner surface 118 and an outer surface 120, all of which may be generally flat or may be radiused to prevent any solid or liquid accumulation during the washing, rinsing and drying process of the bakery tray 100. The wall structure 104 may be angled to flare slightly outwardly from the base 102 to allow for empty nesting of bakery trays 100 as described further below.
The inner surface 118 of the wall structure 104 may be rounded adjacent the corners of the bakery tray 100 (intersection of the side walls 106 and the end walls 108). An upper rim 122 is provided at a top edge 124 of the wall structure 104, wherein the upper rim 122 provides additional support, rigidity, and product containment for the bakery tray 100. With the wall structure 104 flaring outwardly from the base 102, a perimeter of the upper rim 122 is larger than a perimeter of the base 102. The upper rim 122 may have a solid configuration, and may be suitable for optional branding or logo placement. It is also contemplated that the bakery tray 100 could optionally include RFID or bar code technology.
In one or more embodiments, the upper rim 122 has a uniform height above the base 102. In one non-limiting example, a height of the wall structure 104 from the base 102 to the upper rim 122 is between about 2.5 inches and about 3 inches, but it is understood that other dimensions are possible. As with the length and width dimensions, various height dimensions of the bakery tray 100 are contemplated based on the particular baked good product, application, rack compatibility, automation, processing equipment, and customer-specific supply chain variables.
With reference now to
In one non-limiting embodiment, the edge tabs 132 may be generally rectangular. As best shown in the cross-sectional view of
As mentioned above, the bakery tray 100 is nestable with other like trays when empty, such as for conserving storage space.
During nesting, the second bakery tray 100b is configured to be nested within the first bakery tray 100a with the plurality of nesting tabs 126a of the first bakery tray 100a supporting the bottom surface 116b of the second bakery tray 100b such that the upper rim 122b of the second bakery tray 100b is disposed above the upper rim 122a of the first bakery tray 100a. More particularly, the bottom surface 116b of the second base 102b of the second bakery tray 100b is arranged to abut and rest upon the nesting tabs 126a of the first bakery tray 100a, with the wall structure 104b of the second bakery tray 100b abutting the wall structure 104a of the first bakery tray 100a. The nesting tabs 126a prevent the first bakery tray 100a and the second bakery tray 100b from sticking together when nested, and leave the upper rim 122b of the second bakery tray 100b exposed. In this way, the upper rim 122b of the second bakery tray 100b can be easily grasped when the first bakery tray 100a and the second bakery tray 100b are to be separated. The minimal height of the nesting tabs 126a allows for a very compact nesting system for optimal storage efficiency.
As shown in
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
This application claims the benefit of U.S. provisional application Ser. No. 63/434,248 filed Dec. 21, 2022, the disclosure of which is hereby incorporated in its entirety by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63434248 | Dec 2022 | US |
