BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and, together with the general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the present invention.
FIG. 1 depicts a top right perspective view of a first exemplary produce tray assembly that includes an exemplary produce tray in use to hold an apple when horizontally stacked in a box with other produce trays, where the apple, the box, and other produce trays are shown in broken lines;
FIG. 2 depicts top right perspective view of the produce tray assembly of FIG. 1, with the produce tray oriented in a vertical position with respect to the box and other produce trays, where the box and other produce trays are shown in broken lines;
FIG. 3 depicts a top right perspective view of the produce tray of FIG. 1;
FIG. 4 depicts a bottom left perspective view of the produce tray of FIG. 1;
FIG. 5 depicts a front elevational view of the produce tray of FIG. 1, the rear side of the produce tray being a mirror image thereof;
FIG. 6 depicts a right side elevational view of the produce tray of FIG. 1;
FIG. 7 depicts a left side elevational view of the produce tray of FIG. 1;
FIG. 8 depicts a top plan view of the produce tray of FIG. 1;
FIG. 9 depicts a bottom plan view of the produce tray of FIG. 1,
FIG. 10 depicts a top right perspective view of the produce tray similar to FIG. 3 but using all solid lines;
FIG. 11 depicts a bottom left perspective view of the produce tray of FIG. 10;
FIG. 12 depicts a front elevational view of the produce tray of FIG. 10, the rear side of the produce tray being a mirror image thereof;
FIG. 13 depicts a right side elevational view of the produce tray of FIG. 10;
FIG. 14 depicts a left side elevational view of the produce tray of FIG. 10;
FIG. 15 depicts a top plan view of the produce tray of FIG. 10;
FIG. 16 depicts a bottom plan view of the produce tray of FIG. 10;
FIG. 17 depicts a top right perspective view of a second exemplary produce tray assembly that includes an exemplary produce tray in use to hold an apple when horizontally stacked in a box with other produce trays, where the apple, the box, and other produce trays are shown in broken lines;
FIG. 18 depicts a side cross-sectional view of the produce tray assembly of FIG. 17;
FIG. 19 depicts top right perspective view of the produce tray assembly of FIG. 17, with a lower row of produce trays oriented in a vertical position and an upper row of produce trays arranged in a horizontal position with respect to the box, where the box and other produce trays are shown in broken lines;
FIG. 20 depicts a side cross-sectional view of the produce tray assembly of FIG. 19;
FIG. 21 depicts a top right perspective view of the produce tray of FIG. 17;
FIG. 22 depicts a bottom left perspective view of the produce tray of FIG. 17;
FIG. 23 depicts a front elevational view of the produce tray of FIG. 17, the rear side of the produce tray being a mirror image thereof;
FIG. 23A depicts an enlarged schematic sectional view of the base of FIG. 23 taken along line 23A-23A of FIG. 23;
FIG. 24 depicts a right side elevational view of the produce tray of FIG. 17;
FIG. 25 depicts a left side elevational view of the produce tray of FIG. 17;
FIG. 26 depicts a top plan view of the produce tray of FIG. 17;
FIG. 27 depicts a bottom plan view of the produce tray of FIG. 17,
FIG. 28 depicts an exemplary method of manufacturing the produce tray assemblies of FIGS. 1-2 and 17-20;
FIG. 29A depicts two produce trays of FIG. 23 nested together;
FIG. 29B depicts produce being inserted into the produce tray of FIG. 29A while the produce tray is on a conveyor;
FIG. 29C depicts the produce tray of FIG. 29B but with the handle in the folded position and film applied;
FIG. 29D depicts the produce tray of FIG. 29C after a knife severs excess film from the produce tray; and
FIG. 29E depicts the produce tray of FIG. 29D ready to be inserted into the box of FIGS. 17-20.
The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.
DETAILED DESCRIPTION
The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.
To the extent that spatial terms such as “upper,” “lower,” “vertical,” “horizontal,” “top,” “bottom,” or the like are used herein with reference to the drawings, it will be appreciated that such terms are used for exemplary description purposes only and are not intended to be limiting or absolute. In that regard, it will be understood that devices such as those disclosed herein may be used in a variety of orientations and positions not limited to those shown and described herein. Further, the terms “about” and “approximately” as used herein for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein.
I. Exemplary Produce Tray Assemblies
A. First Exemplary Produce Tray Assembly
FIGS. 1-2 show a first exemplary produce tray assembly (10) that includes a plurality of produce trays (12) and a box (14). Produce trays (12) are used to hold produce therein. Produce trays (12) are positioned in box (14) in a horizontal position or a vertical position. Particularly, FIG. 1 shows produce tray assembly (10) an exemplary produce tray (12) in use to hold produce, such as apple (A), when horizontally stacked in box (14), with apple (A), box (14), and other produce trays (12) in broken lines. Box (14) is configured to hold a first number of produce trays (12) in response to produce trays (12) being positioned in a horizontal position. FIG. 1 shows box (14) holding six produce trays (12) in the horizontal position, with six produce trays (12) being arranged in two stacks of produce trays (12) that are three produce trays (12) deep.
Box (14) is configured to a second number of produce trays (12) in response to produce trays (12) being positioned in a vertical position. Particularly, FIG. 2 shows produce tray assembly (10) with produce trays (12) oriented in the vertical position with respect to box (14), with box (14) and other produce trays (12) being shown in broken lines. The second number of produce trays (12) is greater than the first number of produce trays (12). FIG. 2 shows box (14) holding seven produce trays (12) in the vertical position.
FIGS. 3-16 show a single produce tray (12) of FIGS. 1-2 from various angles. FIGS. 3-9 show select portions of product tray (12) in broken lines, while FIGS. 10-16 show produce tray (12) using solid lines. As shown in FIGS. 3-16, produce tray (12) includes a plurality of bases (16a-l), a plurality of inner sidewalls (18), a plurality of outer sidewalls (20), a lip (22), a handle (24), and at least one post (shown as posts (26a-f)). Inner sidewalls (18), outer sidewalls (20), and posts (26a-f) form a plurality of cavities (28a-l). Inner sidewalls (18) and outer sidewalls (20) extend from bases (16a-l). Cavities (28a-l) of produce tray (12) are sized and configured to retain produce, with an apple (A) being shown in FIG. 1. Produce tray (12) includes first, second, third, and fourth sides (30, 32, 34, 36). Handle (24) extends outwardly from first side (30), and includes an aperture (37). First side (30) is disposed opposite second side (32). Similarly, third side (34) is disposed opposite fourth side (36). Outer sidewalls (20) of first and second sides (30, 32) include recessed portions (46). Bases (16a-l) define a lower most surface (38) of produce tray (12) in the horizontal position.
As shown in FIGS. 5-7 and FIGS. 12-14, lip (22) extends from outer sidewalls (20). Lip (22) includes a planar surface (40). Planar surface (40) of lip (22) extends outwardly from outer sidewalls (20). Handle (24) extends outwardly from lip (22). When produce tray (12) is in the horizontal position of FIG. 1, handle (24) extends horizontally. When produce tray (12) is in the vertical position of FIG. 2, handle (24) extends upwardly. As shown in FIGS. 3, 5-10, and 12-16, posts (26a-f) extend from inner sidewalls (18) in a direction away from base (16). Posts (26a-f) each include a planar surface (42). Posts (26a-f) are positioned at the convergence of four adjacent inner sidewalls (18). As shown in FIGS. 5-7 and FIGS. 12-14, planar surfaces (42) of posts (26a-f) are coplanar with planar surface (40) of lip (22). Planar surfaces (42) of posts (26a-f) and planar surface (40) of lip collectively define an upper most surface (44) of produce tray (12) in the horizontal position.
Twelve cavities (28a-l) are shown and are arranged in an array. As shown in
FIGS. 8-9 and 15-16, cavities (28a-d) are arranged in a first row. Cavities (28e-h) are arranged in a second row. Cavities (28i-l) are arranged in a third row. Cavities (28a, 28e, 28i) are arranged in a first column. Cavities (28b, 28f, 28j) are arranged in a second column. Cavities (28c, 28g, 28k) are arranged in a third column. Cavities (28d, 28h, 28l) are arranged in a fourth column.
Cavity (28a) is formed by base (16a), adjacent outer sidewalls (20) of first and third sides (30, 34), two adjacent inner sidewalls (18), and post (26a) that extends from inner sidewalls (18) in a direction away from base (16a). Cavity (28b) is formed by base (16b), outer sidewall (20) of first side (30), three adjacent inner sidewalls (18), and posts (26a, 26b) that extend from inner sidewalls (18) in a direction away from base (16b). Cavity (28c) is formed by base (16c), outer sidewall (20) of first side (30), three adjacent inner sidewalls (18), and posts (26b, 26c) that extend from inner sidewalls (18) in a direction away from base (16c). Cavity (28d) is formed by base (16d), adjacent outer sidewalls (20) of first and fourth sides (30, 36), two adjacent inner sidewalls (18), and post (26c) that extends from inner sidewalls (18) in a direction away from base (16d).
With continued reference to FIGS. 8-9 and 15-16, cavity (28e) is formed by base (16e), outer sidewall (20) of third side (34), three adjacent inner sidewalls (18), and posts (26a, 26d) that extend from inner sidewalls (18) in a direction away from base (16e). Cavity (280 is formed by base (160, four inner sidewalls (18), and posts (26a, 26b, 26d, 26e) that extend from inner sidewalls (18) in a direction away from base (16f). Cavity (28g) is formed by base (16g), four inner sidewalls (18), and posts (26b, 26c, 26e, 260 that extend from inner sidewalls (18) in a direction away from base (16g). Cavity (28h) is formed by base (16h), outer sidewall (20) of fourth side (36), three adjacent inner sidewalls (18), and posts (26c, 26f) that extend from inner sidewalls (18) in a direction away from base (16h).
With continued reference to FIGS. 8-9 and 15-16, cavity (28i) is formed by base (16i), adjacent outer sidewalls (20) of second and third sides (32, 34), two adjacent inner sidewalls (18), and post (26d) that extends from inner sidewalls (18) in a direction away from base (16i). Cavity (28j) is formed by base (16j), outer sidewall (20) of first side (30), three adjacent inner sidewalls (18), and posts (26d, 26e) that extend from inner sidewalls (18) in a direction away from base (16j). Cavity (28k) is formed by base (16k), outer sidewall (20) of first side (30), three adjacent inner sidewalls (18), and posts (26e, 26f) that extend from inner sidewalls (18) in a direction away from base (16k). Cavity (28l) is formed by base (16l), adjacent outer sidewalls (20) of first and fourth sides (30, 36), two adjacent inner sidewalls (18), and post (26f) that extends from inner sidewalls (18) in a direction away from base (16l).
B. Second Exemplary Produce Tray Assembly
FIGS. 17-20 show a second exemplary produce tray assembly (110) that includes a plurality of produce trays (112) and a box (114). Produce trays (112) are used to hold produce therein. Produce trays (112) are positioned in box (114) in a horizontal position and/or a vertical position. FIGS. 17-18 show produce tray (112) in use to hold produce, such as apple (A), when horizontally stacked in box (114), with apple (A), box (114), and other produce trays (112) shown in broken lines. Particularly, FIGS. 17-18 show box (114) holding nine produce trays (112) in the horizontal position, with the nine produce trays (112) being arranged in three stacks of produce trays (112) that are three produce trays (112) deep.
FIGS. 19-20 show produce tray assembly (110) with produce trays (112) oriented in the vertical position with respect to box (114), with box (114) and other produce trays (112) being shown in broken lines. Particularly, FIGS. 19-20 show box (114) holding nine produce trays (112) in the vertical position, with six produce trays (112) being arranged in a vertical position and three produce trays (112) being arranged on top in the horizontal position.
FIGS. 21-27 show a single produce tray (112) of FIGS. 17-20 from various angles. As shown in FIGS. 3-16, produce tray (112) includes a plurality of bases (116a-h), a plurality of inner sidewalls (118), a plurality of outer sidewalls (120), a lip (122), a handle (124), and at least one post (shown as posts (126a-c)). Inner sidewalls (118), outer sidewalls (120), and posts (126a-c) form a plurality of cavities (128a-h). Inner sidewalls (118) and outer sidewalls (120) extend from bases (116a-h). Cavities (128a-h) of produce tray (112) are sized and configured to retain produce, with an apple (A) being shown in FIG. 17. Produce tray (112) includes first, second, third, and fourth sides (130, 132, 134, 136). Handle (124) extends outwardly from first side (130), and includes an aperture (137). First side (130) is disposed opposite second side (132). Similarly, third side (134) is disposed opposite fourth side (136). Outer sidewalls (120) of first and second sides (130, 132) include recessed portions (146). Bases (116a-h) define a lower most surface (138) of produce tray (112) in the horizontal position. As shown in FIGS. 21, 26, and 27, inner sidewalls (118) include generally vertically extending recessed surfaces (148) that may assist in nesting and denesting produce tray (112) relative to another produce tray (12, 112). While generally vertically extending recessed surfaces (148) are shown in groups of three, more or fewer generally vertically extending recessed surfaces (148) are also envisioned. It is also envisioned that generally vertically extending recessed surfaces (148) may extend along only a select portion of inner sidewalls (118) instead of each inner sidewall (118) as shown.
As best shown in FIGS. 21 and 26, lip (122) extends from outer sidewalls (120). Lip (122) includes a planar surface (140). Planar surface (140) of lip (122) extends outwardly from outer sidewalls (120). Handle (124) extends outwardly from lip (122). When produce tray (112) is in the horizontal position of FIGS. 17-18, handle (124) extends horizontally. When produce tray (112) is in the vertical position of FIG. 2, handle (124) extends upwardly. As shown in FIGS. 21, 23, and 24-27, posts (126a-c) extend from inner sidewalls (118) in a direction away from base (116). Posts (126a-c) each include a planar surface (142). Posts (126a-c) are positioned at the convergence of four adjacent inner sidewalls (118). As shown in FIGS. 24-25, planar surfaces (142) of posts (126a-c) are coplanar with planar surface (140) of lip (122). Planar surfaces (142) of posts (126a-c) and planar surface (140) of lip collectively define an upper most surface (144) of produce tray (112) in the horizontal position. Posts (126a-c) may provide additional rigidity to produce tray (112) and may be coupled with film (250 as shown and described below with reference to FIGS. 29C-29E.
FIG. 23A shows an enlarged sectional view of one of bases (116a-h). Bases (116a-h) act as shock absorbers that deflect when a downward pressure is exerted on produce tray (112). This shock absorbing aspect may assist in protecting produce from damage during movement (e.g., during shipment). When downward pressure is exerted on base (116a-h), the area of lower most surface (138) increases due to the deflection. As shown in schematic sectional view of FIG. 23A, the contacting dimension may transition from dimension 1 (D1) when no downward pressure is applied to dimension 2 (D2) when downward pressure is applied. Dimension 1 (D1) is shown in solid lines and dimension 2 (D2) is shown using dashed lines for illustrative purposes. This increase in the contacting dimension allows the force to be transferred though produce tray (112) while having a minimal effect (or no effect) on the produce contained within. The plastic stretches at its thinnest point to provide this shock absorbing capability.
Eight cavities (128a-h) are shown and are arranged in an array. As shown in FIGS. 21 and 26, cavities (128a-d) are arranged in a first row. Cavities (128e-h) are arranged in a second row. Cavities (128a, 128e) are arranged in a first column. Cavities (128b, 128f) are arranged in a second column. Cavities (128c, 128g) are arranged in a third column. Cavities (128d, 128h) are arranged in a fourth column.
As shown in FIGS. 21 and 26, cavity (128a) is formed by base (116a), adjacent outer sidewalls (120) of first and third sides (130, 134), two adjacent inner sidewalls (118), and post (126a) that extends from inner sidewalls (118) in a direction away from base (116a). Cavity (128b) is formed by base (116b), outer sidewall (120) of first side (130), three adjacent inner sidewalls (118), and posts (126a, 126b) that extend from inner sidewalls (118) in a direction away from base (116b). Cavity (128c) is formed by base (116c), outer sidewall (120) of first side (130), three adjacent inner sidewalls (118), and posts (126b, 126c) that extend from inner sidewalls (118) in a direction away from base (116c). Cavity (128d) is formed by base (116d), adjacent outer sidewalls (120) of first and fourth sides (130, 136), two adjacent inner sidewalls (118), and post (126c) that extends from inner sidewalls (118) in a direction away from base (116d).
With continued reference to FIGS. 21, 23, 24-26, cavity (128e) is formed by base (116e), adjacent outer sidewalls (120) of second and third sides (132, 134), two adjacent inner sidewalls (118), and post (126a) that extends from inner sidewalls (118) in a direction away from base (116e). Cavity (128f) is formed by base (116f), outer sidewall (120) of first side (130), three adjacent inner sidewalls (118), and posts (126a, 126b) that extend from inner sidewalls (118) in a direction away from base (116f). Cavity (128g) is formed by base (116g), outer sidewall (120) of first side (130), three adjacent inner sidewalls (118), and posts (126b, 126c) that extend from inner sidewalls (118) in a direction away from base (116g). Cavity (128h) is formed by base (116h), adjacent outer sidewalls (120) of first and fourth sides (130, 136), two adjacent inner sidewalls (118), and post (126c) that extends from inner sidewalls (118) in a direction away from base (116h).
C. Exemplary Method of Manufacture
A method (210) of manufacturing a produce tray (12, 112) is described with reference to FIGS. 28-29E. As shown on FIG. 28, method (210) includes steps (212, 214, 216, 218, 220, 222, 224, 226, 228). As shown, and described, the completed produce tray includes a produce tray (12, 112), film (250), and produce (252).
At step (212), method (210) includes thermoforming produce tray (12, 112) from a polymeric material. For example, produce tray (12, 112) may be thermoformed using polyethylene terephthalate prior to inserting produce (e.g., apple (A)) within cavities (28a-l, 128a-h) of produce tray (12, 112). Produce tray (12, 112) may be formed from full 100% recycled material (e.g., 100% post-consumer recycled material) Additionally, produce tray (12, 112) may be fully recyclable after use. Each produce tray (12, 112) may be integrally formed together as a unitary piece. In some versions, produce trays (12, 112) may be nested together to reduce the amount of space occupied by produce trays (12, 112).
At step (214), method (210) includes denesting produce tray (12, 112) from a stack of produce trays (12, 112) that are nested together. For example, denesting features (shown as recessed portions (46, 146) and/or generally vertically extending recessed surfaces (148)) may be used to assist in denesting produce trays (12, 112) from one another. Recessed portions (46, 146) and/or generally vertically extending recessed surfaces (148) may prevent produce trays (12, 112) from attaching together thereby allowing produce trays (12, 112) to be separated either manually or automatically through the use of a tray denesting machine.
At step (216), method (210) includes inserting produce (252), shown in broken lines, within cavities (28a-l, 128a-h) of produce tray (12, 112). While an apple (A) is shown, a variety of other produce may be inserted into cavities (28a-l, 128a-h) of produce trays (12, 112) including peaches, nectarines, plums, oranges, tomatoes, grapefruit, avocados, or other suitable produce. As shown in FIG. 29B, lower most surface (138) of produce tray (112) may rest on a surface (shown as a conveyor (254)). Produce trays (12, 112) may be washed prior to inserting produce (252) into produce trays (12, 112).
At step (218), method (210) includes applying film (250) to the planar surface of lip (22, 122) of produce tray (12, 112) to seal produce (252) within produce tray (12, 112). In some versions, film (250) may be applied continuously from a roll (not shown). Film (250) includes opposing upper and lower surfaces (256, 258). Lower surface (258) of film (250) may include an adhesive (251). For example, adhesive (251) may be a pressure sensitive and/or heat sensitive adhesive. Film (250) may be biaxially-oriented polypropylene (BOPP), with a wash away adhesive for recycling. Film (250) may be pressed down onto planar surface (40, 140) of lip (22, 122) and to planar surface (42, 142) of post (26a-f, 126a-c) using a roller. In some versions, step (216) may also include applying film (250) to planar surfaces (42, 142) of posts (26a-f) to increase the sealing surface to seal produce within produce tray (12, 112). The planar nature of planar surface (40, 140) of lip (22, 122) and to planar surface (42, 142) of post (26a-f, 126a-c) may assist with the adhesion and retention of film (250). As shown in FIG. 29C, first and second guide rails (260, 262) may be used to align and orient produce tray (12, 112) along conveyor (254). In some versions, a rail (e.g., a sled) may be used to fold handle (24, 124) from the extended position to the folded position as produce tray (12, 122) simultaneously moves along a conveyor (254).
At step (220), method (210) includes folding handle (24, 124) of produce tray (12, 112) from the extended position (see FIG. 29B) to the folded position (see FIG. 29C). In the folded position, handle (24, 124) is generally perpendicular to the position of handle (24, 124) in the extended position.
At step (222), method (210) includes cutting film (250) while handle (24, 124) is folded down in the folded position. As shown in FIG. 29D, For example, a knife (264) may be used to cut film (250) and remove extra portions (250a).
At step (224), method (210) includes inserting produce trays (12, 112) (after produce (252) has been inserted and film (250) has been applied) within box (14, 114) in a vertical position with handle (24) in the extended position. Alternatively, some produce trays (12, 112) (see FIGS. 19-20) or each produce trays (12, 112) (see FIG. 1 and FIGS. 17-18) may be inserted into box (14, 114) in the vertical position.
At step (226), method (210) includes inserting additional produce trays (12, 112) (after produce (252) has been inserted and film (250) has been applied) in a vertical position on top of produce tray (12, 112) within box (14, 114). It may be desirable to completely fill box (14, 114) with produce trays (12, 112). Inserting produce trays (12, 112) in the vertical position may increase the density of produce trays (12, 112) allowing for more produce trays (12, 112) to be placed into box (14, 114). This increased density allows for greater produce trays (12, 112) per truckload to reduce transportation costs and associated emissions. With respect to produce tray assembly (110) shown in FIGS. 19-20, inserting produce tray (122) in the horizontal position on top of produce trays (12, 122) in the vertical position may cause handle (24) to pivot from the extended position to the folded position.
At step (228), method (210) includes a user manually grabbing handle (24) to remove produce tray (12, 112) from box (14, 114). In some versions, user may manually grab handle (24) after handle (24, 124) springs back to the extended position from the folded position as the film (250) is vertically oriented. Having handle (24, 124) in vertical position, enable a user to “grab and go” with produce tray (12, 112). Handle (24, 124) is configured to support the weight of produce tray (12, 112). For example, produce tray (12, 112) may weigh about four pounds.
II. Miscellaneous
It should be understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. that are described herein. The above-described teachings, expressions, embodiments, examples, etc. should therefore not be viewed in isolation relative to each other. Various suitable ways in which the teachings herein may be combined will be readily apparent to those of ordinary skill in the art in view of the teachings herein. Such modifications and variations are intended to be included within the scope of the claims.
Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometrics, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.
Patent Application
20230017541
