Dairy tray system

Abstract

A tray includes a base having an upper support surface and a central portion extending downward to define a lowermost surface of the tray. The base includes a peripheral portion recessed relative to the central portion. A pair of opposed first walls extend along opposed first edges of the base. A pair of opposed second walls extending along opposed second edges of the base.

Description

BACKGROUND

Some products, such as dairy products in retail store, are often shipped to the store in containers, such as trays. The loaded trays may be stacked by hand onto a pallet. The loaded pallet is then shipped to the store, where the loaded trays are removed from the pallet by hand. The products may be removed from the trays by hand and loaded onto a shelf in a refrigerator.

SUMMARY

A tray includes a base having an upper support surface and a central portion extending downward to define a lowermost surface of the tray. The base includes a peripheral portion offset upwardly relative to the central portion. Fork tines of a lift may be received under the peripheral portion of the base to lift the tray off the floor. A pair of opposed first walls extend along opposed first edges of the base. A pair of opposed second walls extending along opposed second edges of the base.

The tray may include a plurality of upper column portions along an inner periphery of the first walls and second walls. The tray may also including a plurality of lower column portions between and below the plurality of upper column portions.

The tray may be a first tray in a multiple tray system that further includes a second tray with the same footprint as the first tray. The second tray is also substantially similar to the first tray, but is configured for different size containers. For example, the second tray may have upper column portions that project into the tray further than those of the first tray.

The trays disclosed herein perform similarly to both a pallet and a secondary packaging tray. Therefore, the cross section is significantly increased compared to the beverage crates currently in the market. The rib structure of the base reaches the bottom of the tray and the rib structure of the peripheral portion of the base (the lifting surface or ledge) reaches the base of that feature.

The trays disclosed herein stacked on a pallet can be shopped directly out of in the store. When a tray is empty, it can be set aside, nested, or stored and the next tray with primary packaging below can be shopped. When a tray is behind a cooler door and half shopped, the primary packaging can slide to the front manually because the inside surface is not broken or pocketed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a dairy tray system including a first tray and a second tray.

FIG. 2 is a perspective view of the first tray of FIG. 1.

FIG. 3 is a bottom perspective view of the first tray.

FIG. 4 is a top view of the first tray.

FIG. 5 is a bottom view of the first tray.

FIG. 6 is a bottom perspective view of the first tray.

FIG. 7 is a perspective view of an alternative first tray.

FIG. 8 is a bottom perspective view of the alternative first tray.

FIG. 9 is another alternative tray.

FIG. 10 is a bottom perspective view of the tray of FIG. 9.

FIG. 11 is a top view of the tray of FIG. 9.

FIG. 12 is a bottom view of the tray of FIG. 9.

FIG. 13 shows three of the trays of FIG. 2 nested and empty.

FIG. 14 shows another alternate first tray.

FIG. 15 is a perspective view of another alternate first tray.

FIG. 16 is a perspective view of another alternate first tray.

FIG. 17 is a perspective view of another alternate first tray.

FIG. 18 shows a plurality of the first trays of FIG. 2 loaded with containers and stacked on one another on a pallet.

FIG. 19 shows three of the first trays of FIG. 18 empty and nested.

FIG. 20 shows a plurality of the second trays of FIG. 1 empty and nested.

FIG. 21 shows the second tray of FIG. 1 fully nested in the first ray of FIG. 1.

FIG. 22 shows the first tray of FIG. 1 partially nested in the second tray of FIG. 1.

FIG. 23 shows a fork tine set that can be used to lift the any of the trays.

FIG. 24 shows the fork tine set of FIG. 23 beginning to move under an alternate first tray.

FIG. 25 shows the fork tine set and tray of FIG. 24, with the fork tine set supporting the tray.

FIG. 26 is a perspective view of the tray of FIG. 24.

FIG. 27 is a bottom perspective view of the tray of FIG. 26.

FIG. 28 is a top view of the tray of FIG. 26.

FIG. 29 is a bottom view of the tray of FIG. 26.

FIG. 30 is a side view of the tray of FIG. 26.

FIG. 31 is an end view of the tray of FIG. 26.

FIG. 32 is a perspective of an alternate second tray.

FIG. 33 is a bottom perspective view of the tray of FIG. 32.

FIG. 34 is a top view of the tray of FIG. 32.

FIG. 35 is a bottom view of the tray of FIG. 32.

FIG. 36 is a side view of the tray of FIG. 32.

FIG. 37 is an end view of the tray of FIG. 32.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

A dairy tray system according to one embodiment is shown in FIG. 1. The dairy tray system includes a plurality of first trays 10 (one shown) for holding large containers, such as one-gallon milk jugs 90 and a plurality of second trays 110 (one shown) for holding smaller containers, such as half-gallon milk jugs 190. The first tray 10 holds the one-gallon jugs 90 in a 4×3 array while the second tray 110 holds the half-gallon milk jugs 190 in a 4×5 array; however, both trays 10, 110 have the same footprint (width and length) and height. In this example, the internal dimensions vary in order to accommodate the different size containers 90, 190.

FIG. 2 is a perspective view of the first tray 10. The example first tray 10 is formed as a single piece of plastic, such as by injection molding, but other methods could be used. The tray 10 includes a base 12, opposed side walls 14 and opposed end walls 16. Spaced-apart upper column portions 18 are formed along the inner periphery of the side walls 14 and end walls 16. The upper column portions 18 taper upward and have an uppermost surface coplanar with the uppermost edges of the side walls 14 and end walls 16. Lower ribs 20 extend between lower portions of adjacent pair of upper column portions 18. Perpendicular ribs 21 extend from each lower rib 20 to a lower portion of the side wall 14 or end wall 16.

Interconnected, transverse peripheral ribs 22 extend about the periphery of the base 12 adjacent and inward of the upper column portions 18. Container support areas each include a center annular wall 24, radial ribs 26, an annular rib 28 and interconnected, transverse ribs 29 extending outward from the annular rib 28. Horizontal strips 30 extend longitudinally and laterally across the support surface of the base 12, generally along the borders of the container support areas.

Angled wall portions 34 cut the corners of the tray 10 and connect the side walls 14 to each adjacent end wall 16. Recessed lower corner walls 36 define a de-nesting notch 35 below each angled wall portion 34. Lower column portions 40 are positioned between and below the upper column portions 18 and extend below the lower edges of the side walls 14 and end walls 16. The lower column portions 40 are tapered downward. Chamfered corners assist with tray separation from adjacent trays when palletized by creating hole for person's hand to slip in-between trays.

FIG. 3 is a bottom perspective view of the tray 10. As shown, the lowermost edges of the lower column portions 40 are coplanar with a horizontal peripheral wall portion 42, which extends about the periphery of the base 12. The horizontal peripheral wall portion 42 is inward of the lower column portions 40. The plurality of peripheral ribs 22 of FIG. 2 extend downward to the horizontal peripheral wall portion 42. This provides strong support between fork tines and the upper surface of the base 12 of the tray 10. A lower peripheral rib 44 projects downward generally perpendicularly at an inner edge of the horizontal peripheral wall portion 42. A central portion of the base 12 is defined by the lower peripheral rib 44. The central portion includes the lower peripheral rib 44 and a plurality of interconnected, transverse ribs 46. The central portion further includes concave, angled and/or contoured, somewhat conical surfaces 48 that are complementary to the upper surfaces of the large containers 90 (FIG. 1). The interconnected, transverse ribs 46 extend downward from the horizontal strips 30 shown in FIG. 2 to provide strong support from the weight of the containers 90 down to the floor. The radial ribs 26, the annular rib 28 and the interconnected, transverse ribs 29 of each container support area shown in FIG. 2 extend upward from the contoured surfaces 48 of FIG. 3. This provides strong support between the lower surfaces of the containers 90 in the tray 10 down to the upper surfaces of the containers 90 stacked therebelow.

The central portion of the base 12 extends lower than the horizontal peripheral wall portion 42 and the lower column portions 40, such that while the central portion is supported on a floor, the horizontal peripheral wall portion 42 and the lower column portions 40 provide surfaces that can be lifted by fork tines or the like.

Bottom edges 50 of the recessed lower corner areas 36 may be contoured convexly and can be used to manually lift a loaded tray 10 (by more than one person). The contours also improve the ergonomics for lifting the tray 10.

FIG. 4 is a top view of the first tray 10. Dashed lines in FIG. 4 show the general delineation of the 12 container support areas 54 defined on the base, which has some correlation to the horizontal strips 30 in the base 12.

FIG. 5 is a bottom view of the first tray 10. In FIG. 5, between the dashed lines is defined a load bearing periphery 56 that can be used to contact fork tines or other support surfaces to support the tray 10. The load bearing periphery 56 includes a plurality of coplanar surfaces, including the horizontal peripheral wall portion 42 and the lowermost edges of the lower column portions 40. The load-bearing periphery is wide enough to be supported on fork tines, for example, at least 1.5″ wide.

FIG. 6 is a bottom perspective view of the tray 10. As shown, the central portion of the bottom of the tray 10 is lower than the load bearing periphery 56, which includes horizontal peripheral wall portion 42 and the lower edges of the lower column portions 40. The central portion includes the plurality of transverse ribs 46 and the peripheral rib 44.

FIG. 7 is a perspective view of an alternative first tray 10a. The first tray 10a is identical to the first tray 10 of FIGS. 1-6 except as otherwise described below or shown in the drawings. The tray 10a has a base 12a and the same sidewalls 14 and end walls 16 as before. The periphery of the base 12a includes an upper horizontal peripheral wall 42a. (In the first embodiment, this area included a plurality of ribs.)

FIG. 8 is a bottom perspective view of the alternative first tray 10a. As shown, in this embodiment, the load bearing area 56a around the periphery of the tray 10a is defined by a plurality of interconnecting transverse ribs 22a that extend downward from the horizontal peripheral wall 42a (FIG. 7). This embodiment is not as strong as the first embodiment but provides a more continuous surface on the top of the base in contact with the containers.

FIG. 9 is another alternative tray 10b in which the periphery of the base 12b includes alternating upper horizontal walls 43b and interconnecting transverse ribs 22b. On the underside of the tray 10b, shown in FIG. 10, the tray 10b includes alternating lower wall surfaces 23b and ribs 42b. The ribs 42b extend downward from the upper horizontal walls 43b (FIG. 9). The lower wall surfaces 23b are at lower ends of the ribs 22b (FIG. 9). FIG. 11 is a top view of the alternate tray 10b. FIG. 12 is a bottom view of the alternate tray 10b. This embodiment is a compromise or hybrid between the first two embodiments.

FIG. 13 shows three of the trays 10 nested and empty. The alternate trays 10a and 10b would nest the same way. When nested, the lower column portions 40 of an upper tray 10 are received between the upper column portions 18 of the lower tray 10 until the lower edges of the side walls 14 and end walls 16 the upper edges of the side walls 14 and end walls 16 of the lower tray. This exposes the de-nesting notch 35 which facilitates removing the upper tray from the lower tray.

FIG. 14 shows another alternate first tray 10c, having a first visual identifier 60c, which in this example is a hole through one of the side walls 14c. The hole 60c in the side wall 14c may be visible by an electric eye of automatic handling equipment to verify the orientation of the tray 10c or to distinguish a first tray 10c from a second tray 110 (FIG. 1).

FIG. 15 is a perspective view of another alternate first tray 10d in which a visual identifier 60d formed in side wall 14d is a notch 60d at a lower edge of one of the side walls 14d.

FIG. 16 is a perspective view of another alternate first tray 10e in which a visual identifier 60e formed in side wall 14e is a recessed portion.

FIG. 17 is a perspective view of another alternate first tray 10f in which a visual identifier 60f formed in side wall 14f is a raised logo and/or characters. The variations in the alternate first trays 10a-f could also be incorporated into second tray 110.

As shown in FIG. 18, a plurality of the first trays 10 can be loaded with containers 90 and stacked on one another on a pallet 200. The trays 10, containers 90 and pallet 200 are shipped to a store where they are sold to customers. When the trays 10 are empty, they can be nested as shown in FIG. 19. Generally, the lower column portions 40 of an upper tray 10 are received between the upper column portions 18 of the lower tray 10 and the base 12 of the upper tray 10 is received between the upper column portions 18 of opposed side walls 14 and opposed end walls 16 of the lower tray 10.

FIG. 20 shows a plurality of the second trays 110. The second trays 110 are identical to the first trays 10 except as described or shown differently in the drawings. Generally, the second trays 110 include upper column portions 118 that project inward from the side walls 114 and end walls 116 further than did the upper column portions 18 in the first tray 10. This is to provide a tighter fit with the smaller containers 190 (FIG. 1). The base 112 of the second tray 110 is also arranged in a 4×5 array to accommodate the smaller containers. The depth of the upper column portions 118 may vary based upon the side of the containers and based upon the arrangement on the base 112 (e.g. 3×4, 4×5, 4×4, etc). As also shown in FIG. 20, the empty second trays 110 could also be nested when empty. Again when nested, generally, the lower column portions 140 of an upper tray 110 are received between the upper column portions 118 of the lower tray 110 and the base 112 of the upper tray 110 is received between the upper column portions 118 of opposed side walls 114 and opposed end walls 116 of the lower tray 110.

Many stores will sell both larger containers 90 (FIG. 1) and smaller containers 190 (FIG. 1), so both trays 10, 110 may be used together in the system. Customers can select and remove containers 90, 190 directly out of the trays 10, 110 on the pallet 200 in the store. When a tray 10, 110 is empty, it can be set aside, nested, or stored and the next tray 10, 110 with containers 90, 190 below can be shopped. When a tray 10, 110 is behind a cooler door and half shopped, the containers 90, 190 can slide to the front manually because the inside surface is not broken or pocketed.

As shown in FIG. 21, the empty second tray 110 can be fully nested into the first tray 10 (i.e. the base 112 is received below the upper edge of the upper column portions 18 and the upper edges of the side walls 14 and end walls 16).

As shown in FIG. 22, the first tray 10 only partially nests into the second tray 110. The base 12 is supported on the upper edges of the deeper upper column portions 118.

The trays 10, 110 are compatible with a wide variety of general conveyance equipment, including but not limited to the following: chain, roller, and flat belt conveyors. It contains a base 12, 112 that is mostly coplanar. Any type of conveyance equipment can grab the tray 10, 110 because the ribs making up the cross section of the base 12, 112 also reach the base of the tray for a surface to roll/conveyor, or slide on.

The example trays 10, 110 provide a 4×3 Gallon and a 5×4 Half Gallon footprint trays. The number of bottles on a tray can be adapted and engineered to what best suits a particular pallet or trailer packout. The compatibility of ½ gallon and gallon two trays depend on the bottle count ratios and have been engineered to work together in this example in the same external footprint.

FIG. 23 shows a fork tine set 200 that can be used to lift the any of the trays. The fork tine set 200 can be on any sort of lift for lifting a stack of trays, such as a fork lift, automated handling equipment, etc.

FIG. 24 shows the fork tine set 200 of FIG. 23 beginning to move under a tray 10g. The tray 10g is another alternate tray 10g. The tray 10g is identical to the tray 10 of FIG. 2 except as otherwise shown or described below. In FIG. 24, the fork tines 202 are moved to a position partially inserted below the load bearing periphery 56g, including the lowermost edges of the lower column portions 40g.

FIG. 25 shows the fork tine set 200 and tray of FIG. 24, with the fork tine set supporting the tray 10g. The fork tines 202 are received below the load bearing periphery 56g, including the lower column portions 40g. The central portion of the bottom of the tray 10g, including the peripheral rib 44g, is received between the fork tines 202, further stabilizing the tray 10g on the fork tine set 200. In practice, the fork tine set 200 would be lifting a stack of loaded or empty trays, but only one tray 10g is shown for illustration. The fork tine set 200 would work with all of the trays disclosed herein the same way.

FIG. 26 more clearly shows the tray 10g of FIG. 24. The tray 10g includes a pair of side walls 14g and a pair of end walls 16g. In this embodiment, there are fewer upper column portions 18g (one per container support area) and lower column portions 40g and the corners have been rounded. On the side walls 14g and end walls 16g, the perpendicular ribs 21g project inward from outer walls 23g of the lower column portions 40g, which are connected to and only slightly inwardly offset from the side wall 14g. The outer walls 23g of the lower column portions 40g are a little shorter than the perpendicular ribs 21g. On the end walls 16g only, there are also lower ribs 20g connected to the inner ends of the perpendicular ribs 21g. The lower ribs 20g are shorter than the perpendicular ribs 21g and are generally parallel to the end walls 16g.

FIG. 27 is a bottom perspective view of the tray 10g. As shown, the lowermost edges of the lower column portions 40g are coplanar with a horizontal peripheral wall portion 42g, which extends about the periphery of the base 12g. The horizontal peripheral wall portion 42g is inward of the lower column portions 40g. A lower peripheral rib 44g projects downward generally perpendicularly at an inner edge of the horizontal peripheral wall portion 42g. A central portion of the base 12g is defined by the lower peripheral rib 44g. The central portion includes the lower peripheral rib 44g and a plurality of interconnected, transverse ribs 46g. The central portion further includes concave, angled and/or contoured, somewhat conical surfaces 48g that are complementary to the upper surfaces of the large containers 90 (FIG. 1).

The central portion of the base 12g extends lower than the horizontal peripheral wall portion 42g and the lower column portions 40g, such that while the central portion is supported on a floor, the horizontal peripheral wall portion 42g and the lower column portions 40g provide surfaces that can be lifted by fork tines or the like.

FIG. 28 is a top view of the first tray 10g. FIG. 29 is a bottom view of the first tray 10g. FIG. 30 is a side view of the tray 10g including side wall 14g. Stacking ribs 62g keep a little space between nested empty trays 10g to facilitate separate. FIG. 31 is an end view of the tray 10g including end wall 16g. A contoured cutaway 64g provides a gap for a user to be able to separate nested empty trays 10g.

FIG. 32 is a perspective of an alternate second tray 110g configured to work with the alternate first tray 10g in the same manner as the trays 10, 110 of FIG. 1. The columns 118g project further into the tray 110g than those of the first tray 10g to accommodate the smaller containers 190 (FIG. 1). The tray 110g is configured to have a 4×5 container support areas. The lower column portions 140g also project inward of the second tray 110g further than those of the first tray 10g, as is further shown in FIG. 33. As shown in FIG. 33, the lower peripheral rib 144g projects downward just inward of the lower column portions 140g (with just a small ledge in between). The central portion further includes concave, angled and/or contoured, somewhat conical surfaces 148g that are complementary to the upper surfaces of the small containers 190 (FIG. 1).

FIG. 34 is a top view of the second tray 110g. FIG. 35 is a bottom view of the second tray 110g. FIG. 36 is a side view of the second tray 110g. FIG. 37 is an end view of the second tray 110g.

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.

Claims

1. A tray comprising: a base having an upper support surface, the base including a central portion extending downward from the upper support surface to define a lowermost surface of the tray, the base including a peripheral portion extending downward from the upper support surface less than the central portion, the peripheral portion extending continuously around the central portion of the base;a pair of opposed first walls extending along opposed first edges of the base; anda pair of opposed second walls extending along opposed second edges of the base, the upper support surface defined from one of the opposed first walls to the other of the opposed first walls and from one of the opposed second walls to the other of the opposed second walls.

2. The tray of claim 1 wherein the peripheral portion extends below the upper support surface of the base.

3. The tray of claim 2 wherein the base includes a plurality of vertical first ribs defining the peripheral portion and a plurality of vertical second ribs defining the central portion, and wherein the second ribs are longer than the first ribs such that a lower surface of the peripheral portion is recessed relative to a lowermost surface of the central portion.

4. The tray of claim 3 wherein the central portion includes a plurality of concave recesses on a lower surface thereof, the plurality of recesses each configured to receive an upper portion of a container sized to be shipped in the tray.

5. The tray of claim 1 further including a plurality of upper column portions projecting inward from an inner periphery of the first walls.

6. The tray of claim 5 further including a plurality of lower column portions between and below the plurality of upper column portions.

7. The tray of claim 6 wherein the plurality of lower column portions are spaced apart from one another and project outward from the peripheral portion of the base.

8. The tray of claim 7 wherein lowermost surfaces of the lower column portions are substantially flush with the peripheral portion of the base.

9. The tray of claim 8 wherein the upper column portions are tapered upward and the lower column portions are tapered downward, such that the upper column portions of the tray would be received between the lower column portions of an identical tray nested thereon.

10. The tray of claim 9 wherein the peripheral portion is at least 1.5 inches wide.

11. The tray of claim 10 wherein the tray is molded as a single piece of plastic.

12. The tray of claim 1 wherein the peripheral portion is at least 1.5 inches wide.

13. The tray of claim 1 wherein the peripheral portion is directly below the upper support surface of the base.

14. The tray of claim 13 wherein the peripheral portion is at least 1.5 inches wide.

15. The tray of claim 1 wherein the peripheral portion is between the pair of opposed first walls and between the pair of opposed second walls.

16. A tray system comprising: a first tray having a base, the base having an upper support surface and a central portion extending downward from the upper support surface to define a lowermost surface of the first tray, an underside of the base including a peripheral portion recessed upward relative to the central portion, wherein the peripheral portion is directly below the upper support surface of the base, a lower surface of the central portion of the first tray including a plurality of first concave recesses arranged in 4×3 array, the first concave recesses configured to receive upper ends of first containers, the first tray including a plurality of walls extending proximate the periphery of the base, the plurality of walls defining an outer footprint of the first tray; anda second tray having a base, the base having an upper support surface and a central portion extending downward from the upper surface to define a lowermost surface of the second tray, an underside of the base including a peripheral portion recessed upward relative to the central portion, a lower surface of the central portion of the second tray including a plurality of second concave recesses arranged in 4×5 array, the second concave recesses configured to receive upper ends of second containers, the second tray including a plurality of walls extending proximate the periphery of the base, the plurality of walls of the second tray defining an outer footprint of the second tray, wherein the outer footprint of the first tray is substantially the same as the outer footprint of the second tray.

17. The tray system of claim 16 wherein the first tray is partially nestable in the second tray.

18. The tray system of claim 17 wherein the second tray is nestable in the first tray.

19. The tray system of claim 18 wherein the first tray includes a plurality of first upper column portions projecting inward a first distance from an inner periphery of the plurality of walls of the first tray, wherein the second tray includes a plurality of second upper column portions projecting inward a second distance from an inner periphery of the plurality of walls of the second tray, wherein the second distance is greater than the first distance.

20. The tray system of claim 16 wherein the first containers are sized to be shipped in the first tray and are received in the first tray, and wherein the second containers are sized to be shipped in the second tray and are received in the second tray.

21. The tray system of claim 20 wherein the peripheral portions of the first tray and the second tray are at least 1.5 inches wide.

22. The tray of claim 16 wherein the peripheral portion is at least 1.5 inches wide.

23. The tray system of claim 16 wherein the concave recesses of the first tray each circumscribe an opening into the central portion of the first tray.

24. A tray comprising: a base having an upper support surface, the base including a central portion extending downward from the upper support surface to define a lowermost surface of the tray, the base including a peripheral portion extending downward from the upper support surface less than the central portion, wherein the peripheral portion includes a plurality of interconnecting transverse ribs extending continuously around the central portion, wherein the central portion includes a plurality of concave recesses on a lower surface thereof, the plurality of recesses each configured to receive an upper portion of a container sized to be shipped in the tray;a pair of opposed first walls extending along opposed first edges of the base;a pair of opposed second walls extending along opposed second edges of the base, the upper support surface defined from one of the opposed first walls to the other of the opposed first walls and from one of the opposed second walls to the other of the opposed second walls;a plurality of upper column portions projecting inward from an inner periphery of the pair of opposed first walls, wherein the upper column portions are coplanar with an uppermost edge of the pair of opposed first walls; anda plurality of lower column portions between and below the plurality of upper column portions, wherein the plurality of lower column portions project outward from the peripheral portion of the base, wherein lowermost surfaces of the lower column portions are substantially flush with the peripheral portion of the base, wherein the tray is molded as a single piece of plastic.

25. The tray of claim 24 wherein the peripheral portion is at least 1.5 inches wide.