BRIEF DESCRIPTION OF THE DRAWINGS
The novel features and advantages of the present invention will best be understood by reference to the detailed description of the preferred embodiments which follows, when read in conjunction with the accompanying drawings, in which:
FIG. 1 is a front perspective view of a nestable, stackable food tray (tray) with substantially vertical walls, interlocking recesses on the sidewalls for zero degree and 180 degree stacking of a second like container, and a first and second handle, according to an embodiment of the present invention.
FIG. 2 is a bottom perspective view of the nestable, stackable food tray shown in FIG. 1.
FIG. 3 is a front view of the tray shown in FIG. 1.
FIG. 4 is a right side view of the tray shown in FIG. 1 illustrating a first handle having scalloped finger recesses along an upper surface of the tray, and further having an elongated, generally rectangular shaped horizontal bottom portion, with substantially circular or oval shaped end portions.
FIG. 5 is a rear view of the tray shown in FIG. 1.
FIG. 6 is a left side view of the tray shown in FIG. 1 illustrating a second handle having an elongated, generally rectangular shaped horizontal bottom portion, with substantially circular or oval shaped end portions.
FIG. 7 is a top view of the tray shown in FIG. 1 illustrating a plurality of fanned drain channels, comprising a general star shape, on an upper surface of a substantially solid base surface of the tray.
FIG. 8 is a bottom view of the tray shown in FIG. 1.
FIG. 9 is a front perspective view of a nestable, stackable food tray (tray) with substantially vertical walls, interlocking recesses on the sidewalls for zero degree and 180 degree stacking of a second like container, and a first and second handle, according to an alternative embodiment of the present invention.
FIG. 10 is a top view of the tray shown in FIG. 9 illustrating a plurality of fanned drain channels, comprising a general star shape, on an upper surface of a substantially solid base surface of the tray.
FIG. 11is a front view of the tray shown in FIG. 9.
FIG. 12 is a right side view of the tray shown in FIG. 9 illustrating the first handle having scalloped finger recesses along an upper surface of the tray, and further having an elongated, generally rectangular shaped horizontal bottom portion, with substantially circular or oval shaped end portions.
FIG. 13 is a left side view of the tray shown in FIG. 9 illustrating the second handle having an elongated, generally rectangular shaped horizontal bottom portion, with substantially circular or oval shaped end portions.
FIG. 14 is a cross sectional view of the tray shown in FIG. 9, along line E-E as shown in FIG. 10, illustrating a cross section view of a stacking receptacle.
FIG. 15 is a cross sectional view of the tray shown in FIG. 9, along line 1-1 as shown in FIG. 10, illustrating a first portion of the scalloped finger recesses of the upper portion of the first handle.
FIG. 16 is a cross sectional view of the tray shown in FIG. 9, along line A2-A2 as shown in FIG. 10, illustrating a second portion of the scalloped finger recesses of the upper portion of the first handle.
FIG. 17 is an expanded view of the tray shown in FIG. 9, illustrating an expanded cross sectional view of the scalloped handle as shown in FIG. 16.
FIG. 18 is an expanded partial top view of the tray shown in FIG. 9.
FIG. 19 is a cross sectional view of the tray shown in FIG. 9, along line C2-C2 as shown in FIG. 18, illustrating an interior view of the first handle.
FIG. 20 is a cross sectional view of the tray shown in FIG.9, along line C1-C1 as shown in FIG. 18, illustrating an interior view of the second handle.
FIG. 21 is a cross sectional view of the tray shown in FIG. 9, along line G-G as shown in FIG. 18, illustrating a cross section view of a stacking receptacle.
FIG. 22 is a bottom perspective view of the nestable, stackable food tray shown in FIG. 9.
FIG. 23 is a bottom view of the tray shown in FIG. 9.
FIG. 24 is a cross sectional view of the tray shown in FIG. 9 along line A-A as shown in FIG. 23 illustrating a first cross-sectional view of a center drain hole portion and surrounding drain channels.
FIG. 25 is a cross sectional view of the tray shown in FIG. 9 along line B-B as shown in FIG. 23 illustrating a second cross-sectional view of a center drain hole portion and surrounding drain channels.
FIG. 26 is a top isometric view of the tray shown in FIG. 1 illustrating a plurality of spacers to contain different types of products substantially motion-free within the tray according to an additional embodiment of the invention.
FIG. 27 is a top view of the tray shown in FIGS. 1 and 26.
FIG. 28 is a front view of the spacer shown in FIG. 26, for use in the tray shown in FIGS. 1 and 9, to contain different types of products substantially motion-free according to an additional embodiment of the invention.
FIG. 29 is a right side view of the spacer shown in FIG. 26.
FIG. 30 is rear view of the spacer shown in FIG. 26.
FIG. 31 is a left side view of the spacer shown in FIG. 26.
FIG. 32 is a top perspective view of the spacer shown in FIG. 26.
FIG. 33 is a bottom perspective view of the spacer shown in FIG. 26.
FIG. 34 is a cross sectional view of the spacer shown in FIG. 26, along line B-B shown in FIG. 28 illustrating a hole and a sloped surface of a stiffener of the spacer.
FIG. 35 is a cross sectional view of the spacer shown in FIG. 26, along line A-A shown in FIG. 28 illustrating an internal portion of the stiffener of the spacer.
FIGS. 36A-36F illustrate a plurality of designs for micro-bumps used on the trays and spacers shown in FIGS. 1 through 35 according to an alternative embodiment of the present invention.
FIG. 37 is a top view of the tray shown in FIG. 1 with sectional line A-A.
FIG. 38 is a cross sectional view of the trays shown in FIGS. 1 and 37 along sectional line A-A as shown in FIG. 37.
FIG. 39 is a top view of a tray retrieval tool.
FIG. 40 is a front isometric view of the two trays shown in FIG. 1 in a 0° stacking orientation according to an embodiment of the present invention.
FIG. 41 is a front isometric view of the two trays shown in FIG. 1 in a 180° stacking orientation according to an embodiment of the present invention.
FIG. 42 is a cross sectional view along line A-A shown in FIG. 7 and line B-B shown in FIG. 8, illustrating location and interaction between a front wall left outer stacking foot cross member of a front wall left outer stacking foot of an upper tray and 0° front wall left outer stacking foot cross member receptacle of a lower tray, when the trays are stacked in a 0° stacking orientation, according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The various features of the preferred embodiments will now be described with reference to the drawing figures, in which like parts are identified with the same reference characters. The following description of the presently contemplated best mode of practicing the invention is not to be taken in a limiting sense, but is provided merely for the purpose of describing the general principles of the invention.
I. Summary of the Exemplary Embodiments of the Invention
Tray 100 comprises a base 2, front wall 4 and rear wall 8, left side wall 10 and right side wall 6, wherein the walls are all substantially orthogonal to each other and the base 2. Tray 100 is preferably constructed from high density polyethylene (HDPE) plastic, though other materials can also be used. Tray 100 is preferably used in the baked product industry to carry products such as loaves of bread, rolls, buns, and other similar products. According to a preferred embodiment of the present invention, however, tray 100 carries flour or corn tortilla products. As one of ordinary skill in the art can appreciate, however, other types of products, or goods, can also be carried in tray 100.
Two or more like trays 100 can be stacked in either a 0° stacking orientation, or a 180° stacking orientation. In the 0° stacking orientation, the upper tray (designated as tray 100′), rests upon a lower tray 100 and faces the same direction. In a 180° stacking orientation, rear wall 8′ of the upper tray 100′ is in the same direction as front wall 4 of lower tray 100. FIG. 40 illustrates a 0° stacking orientation, and FIG. 41 illustrates a 180° stacking orientation according to an embodiment of the present invention.
As briefly described above, tray 100 comprises a base 2, a front wall 4, a left and right side wall 10, 6, and a rear wall 8. Each of the walls further comprises several features that assist in the stacking of like trays 100, and the retrieval of like trays 100 from the stacking orientations. For example, left side wall 10 comprises left side wall rear outer stacking foot 186a, left side wall rear inner stacking foot 186b, left side wall front outer stacking foot 176a, and left side wall front inner stacking foot 176b. Right side wall 6 comprises right side wall rear outer stacking foot 44a, right side wall rear inner stacking foot 44b, right side wall front outer stacking foot 38a, and right side wall front inner stacking foot 38b. Because tray 100 is designed to carry several packages of flour or corn tortillas, and the total weight can be as much as about 54 lbs, tray 100 incorporates additional stacking feet on both the front and rear walls as well. Front wall 4 comprises front side wall left outer stacking foot 78a, front side wall left inner stacking foot 78b, front side wall right outer stacking foot 86a, and front side wall right inner stacking foot 86b. Rear wall 8 comprises rear wall right outer stacking foot 134a, rear wall right inner stacking foot 134b, rear wall left outer stacking foot 124a, and rear wall left inner stacking foot 124b.
As discussed above, trays 100 are designed to carry significant amounts of weight of baked products. For this reason, front wall 4, right side wall 6, rear wall 8 and left side wall 10 are substantially perpendicular to base 2, and each comprises a significant amount of plastic material. Further, separate 0° and 180° stacking receptacles are provided that each comprise several surfaces, among other features, to retain upper tray 100′ in the stacked positions. The stacking receptacles will be discussed in greater detail below. Further, each of front wall 4, right side wall 6, rear wall 8 and left side wall 10 comprises a 180° stacking ledge that sets upon upper surfaces of the respective walls of a lower similar tray 100 when in an 180° stacking orientation. This too will be discussed in greater detail below.
According to other exemplary embodiments of the present invention, substantially glossy free surfaces 278 can be provided on all surfaces of tray 100 and spacers 210, 212. According to a preferred embodiment of the present invention, substantially glossy free surfaces 278 can be provided on outer surfaces 22, 66, 114, and 160 of front wall 4, right side wall 6, rear wall 8, and left side wall 10 such that if one or more stickers were to be placed on the outer surfaces 22, 66, 114, and 160 of front wall 4, right side wall 6, rear wall 8, and left side wall 10, they can be easily removed during a cleaning process. According to a preferred embodiment of the present invention, substantially glossy free surfaces 278 can also be provided on inner surfaces 64, 20, 112, and 158 of front wall 4, right side wall 6, rear wall 8, and left side wall 10 such that if one or more stickers were to be placed on the inner surfaces 64, 20, 112, and 158 of front wall 4, right side wall 6, rear wall 8, and left side wall 10, they can be easily removed during a cleaning process. According to a preferred embodiment of the present invention, substantially glossy free surfaces 278 can also be provided on spacer wall side 224 and/or spacer product side 226 of spacers 210, 212 such that if one or more stickers were to be placed on spacer wall side 224 and/or spacer product side 226 of spacers 210, 212, they can be easily removed during a cleaning process. Substantially glossy free surfaces 278 of left and right side walls 10, 6 are used to prevent or alleviate tray counting devices from mis-reading a single tray as multiple trays. According to an exemplary embodiment of the present invention tray counting devices utilize optical transceivers to count or register trays before, during and after cleaning, and before, during, and after being filled with baked product. According to an exemplary embodiment of the present invention, substantially glossy free surfaces 278 prevent reflection of a light beam from being received by an optical receiver, and may comprise a plurality of micro-bumps, recesses, ribs, grooves, and various other types of markings, indentations and other alterations of the surface, which shall be described in greater detail below. According to a preferred embodiment of the present invention, the light beam is generated by an infra-red transmitter or a laser.
The exemplary embodiments of the preferred embodiments of the present invention shall now be described in greater detail.
II. Components of Tray 100
A. Front Wall 4
As discussed in greater detail below, certain conventions are utilized in describing various components of tray 100. For example, “outer” refers to components that are located proximal to the left and right side walls 10, 6 for components on the front and rear walls 4, 8, and more proximal to front and rear walls 4, 8 for components on the left and right side walls 10, 6, whereas “inner” refers to those components that are located more proximal to a center portion of tray 100.
Referring to FIGS. 1, 3, 7, and 8, front wall 4 includes an inner surface 64 and outer surface 66. Outer surface 66 of front wall 4 includes nameplate area 72. Front wall 4 further includes top surface 70. Two pairs of stacking feet are located on both sides of front wall 4, on outer surface 66; a first pair are located a short distance from left side wall 10 and a second pair are located a short distance from right side wall 6. Located adjacent to left side wall 10 of front wall 4 are front wall left outer stacking foot 78a, and front wall left inner stacking foot 78b. Located adjacent to right side wall 6 of front wall 4 are front wall right outer stacking foot 86a, and front wall right inner stacking foot 86b.
Each of the stacking feet comprise certain common characteristic components. Front wall left outer stacking foot 76a comprises front wall left outer stacking foot flat portion 78a, front wall left outer stacking foot cross member 80a, and front wall left outer stacking foot sloped surface 82a. Front wall left inner stacking foot 76b comprises front wall left inner stacking foot flat portion 78b, front wall left inner stacking foot cross member 80b, and front wall left inner stacking foot sloped surface 82b. Front wall right outer stacking foot 86a comprises front wall right outer stacking foot flat portion 88a, front wall right outer stacking foot cross member 90a, and front wall right outer stacking foot sloped surface 92a. Front wall right inner stacking foot 86b comprises front wall right inner stacking foot flat portion 88b, front wall right inner stacking foot cross member 90b, and front wall right inner stacking foot sloped surface. Front wall right inner stacking foot 86b comprises front wall right inner stacking foot flat portion 88b, front wall right inner stacking foot cross member 90b, and front wall right inner stacking foot sloped surface 92b.
Furthermore, front wall 4 comprises 180° stacking ledge 84 that sits upon upper surface 118 of rear wall 8 when upper tray 100′ is stacked in a 180° stacking orientation on lower tray 100 (as shown in FIG. 41). As can be seen in the above referenced drawings, front wall 4, and its components are substantially wider than conventional trays because of the significant amount of weight tray 100 is designed to carry. Front wall 4 further comprises ventilation slots 74, to provide air flow through tray 100, especially when upper trays 100′, 100″ and so on are stacked upon lower tray 100. Front wall 4 further includes front wall hook area 68 that provides a location for a user to place the hook end of tray retrieving tool 276, as shown in FIG. 39. By incorporating similar structures on all four walls, it is much easier for users to pull tray 100 off other trays or from a tray cleaning area.
Located on inner surface 64 of front wall 4 are receptacles for 0° and 180° stacking. Two pairs of stacking receptacles (a pair of 0° stacking receptacles, and a pair of 180° stacking receptacles) are located on inner surface 64 on the left side of front wall 4, and two pairs of stacking receptacles (a pair of 0° stacking receptacles, and a pair of 180° stacking receptacles) are located on inner surface 64 of the right side of front wall 4. Located at the right side of front wall 4 (as viewed from the interior of tray 100) are 0° front wall left outer stacking foot receptacle 94a, and 0° front wall left inner stacking foot receptacle 94b. Between 0° front wall left outer stacking foot receptacle 94a and 0° front wall left inner stacking foot receptacle 94b is 180° front wall left outer stacking foot receptacle 108a, and to the left of 0° front wall left inner stacking foot receptacle 94b is 180° front wall left inner stacking foot receptacle 108b (as viewed from inside tray 100). Located at the left side of front wall 4 (as viewed from the interior of tray 100) are 180° front wall right outer stacking foot receptacle 104a, and 180° front wall right inner stacking foot receptacle 104b. Between 180° front wall right outer stacking foot receptacle 104a and 180° front wall right inner stacking foot receptacle 104b is 0° front wall right outer stacking foot receptacle 98a, and to the right of 180° front wall right inner stacking foot receptacle 104b is 0° front wall right inner stacking foot receptacle 98b (as viewed from inside tray 100).
As shown in FIG. 7, 0° front wall left outer stacking foot receptacle 94a includes 0° front wall left outer stacking foot cross member receptacle 96a; 0° front wall left inner stacking foot receptacle 94b includes 0° front wall left inner stacking foot cross member receptacle 96b; 0° front wall right outer stacking foot receptacle 98a includes 0° front wall right outer stacking foot cross member receptacle 102a; and 0° front wall right inner stacking foot receptacle 98b includes 0° front wall right inner stacking foot cross member receptacle 102b.
As further shown in FIG. 7, 180° front wall left outer stacking foot receptacle 108a includes 180° front wall left outer stacking foot cross member receptacle 110a; 180° front wall left inner stacking foot receptacle 108b includes 180° front wall left inner stacking foot cross member receptacle 110b; 180° front wall right outer stacking foot receptacle 104a includes 180° front wall right outer stacking foot cross member receptacle 106a; and 180° front wall right inner stacking foot receptacle 104b includes 180° front wall right inner stacking foot cross member receptacle 106b. Operation of the stacking feet and receptacles will be discussed in greater detail below for both the 0° and 180° stacking orientations.
B. Rear Wall 8
Referring to FIGS. 1, 5, 7, and 8, rear wall 8 includes an inner surface 112 and outer surface 114. Outer surface 114 of rear wall 8 includes nameplate area 120. Rear wall 8 further includes top surface 118. Two pairs of stacking feet are located on both sides of rear wall 8, on outer surface 114; a first pair are located a short distance from left side wall 10 and a second pair are located a short distance from right side wall 6. Located adjacent to left side wall 10 of rear wall 8, are rear wall left outer stacking foot 124a, and rear wall left inner stacking foot 124b. Located adjacent to right side wall 6 of rear wall 8 are rear wall right outer stacking foot 134a, and rear wall right inner stacking foot 134b.
Each of the stacking feet comprise certain common characteristic components. Rear wall left outer stacking foot 124a comprises rear wall left outer stacking foot flat portion 126a, rear wall left outer stacking foot cross member 128a, and rear wall left outer stacking foot sloped surface 130a. Rear wall left inner stacking foot 124b comprises rear wall left inner stacking foot flat portion 126b, rear wall left inner stacking foot cross member 128b, and rear wall left inner stacking foot sloped surface 130b. Rear wall right outer stacking foot 134a comprises rear wall right outer stacking foot flat portion 136a, rear wall right outer stacking foot cross member 138a, and rear wall right outer stacking foot sloped surface 140a. Rear wall right inner stacking foot 134b comprises rear wall right inner stacking foot flat portion 136b, rear wall right inner stacking foot cross member 138b, and rear wall right inner stacking foot sloped surface 140b.
Furthermore, rear wall 8 comprises 180° stacking ledge 132 that sits upon upper surface 70 of front wall 8 when upper tray 100′ is stacked in a 180° stacking orientation on lower tray 100 (as shown in FIG. 41). As can be seen in the above referenced drawings, rear wall 8, and its components, are substantially wider than conventional trays because of the significant amount of weight tray 100 is designed to carry. Rear wall 8 further comprises ventilation slots 122, to provide air flow through tray 100, especially when upper trays 100′, 100″ and so on are stacked upon lower tray 100. Rear wall 8 further includes rear wall hook area 116 that provides a location for a user to place the hook end of tray retrieving tool 276, as shown in FIG. 39. By incorporating similar structures on all four walls, it is much easier for users to pull tray 100 off other trays or from a tray cleaning area.
Located on inner surface 112 of rear wall 8 are receptacles for 0° and 180° stacking. Two pairs of stacking receptacles (a pair of 0° stacking receptacles, and a pair of 180° stacking receptacles) are located on inner surface 112 on the left side of rear wall 8, and two pairs of stacking receptacles (a pair of 0° stacking receptacles, and a pair of 180° stacking receptacles) are located on inner surface 112 of the right side of rear wall 8. Located at the right side of rear wall 8 (as viewed from the interior of tray 100) are 180° rear wall right outer stacking foot receptacle 150a, and 180° rear wall right inner stacking foot receptacle 150b. Between 180° rear wall right outer stacking foot receptacle 150a and 180° rear wall right inner stacking foot receptacle 150b is 0° rear wall right outer stacking foot receptacle 146a, and to the left of 180° rear wall right inner stacking foot receptacle 150b is 0° rear wall right inner stacking foot receptacle 146b (as viewed from inside tray 100). Located at the left side of rear wall 8 (as viewed from the interior of tray 100) are 0° rear wall left outer stacking foot receptacle 142a, and 0° rear wall left inner stacking foot receptacle 142b. Between 0° rear wall left outer stacking foot receptacle 142a and 0° rear wall left inner stacking foot receptacle 142b is 180° rear wall left outer stacking foot receptacle 154a, and to the right of 0° rear wall left inner stacking foot receptacle 142b is 180° rear wall left inner stacking foot receptacle 154b (as viewed from inside tray 100).
As shown in FIG. 7, 180° rear wall right outer stacking foot receptacle 150a includes 180° rear wall right outer stacking foot cross member receptacle 152a; 180° rear wall right inner stacking foot receptacle 150b includes 180° rear wall right inner stacking foot cross member hreceptacle 152b; 0° rear wall right outer stacking foot receptacle 146a includes 0° rear wall right outer stacking foot cross member receptacle 148a; and 0° rear wall right inner stacking foot receptacle 146b includes 0° rear wall right inner stacking foot cross member receptacle 148b.
As further shown in FIG. 7, 0° rear wall left outer stacking foot receptacle 142a includes 0° rear wall left outer stacking foot cross member receptacle 144a; 0° rear wall left inner stacking foot receptacle 142b includes 0° rear wall left inner stacking foot cross member receptacle 144b; 180° rear wall left outer stacking foot receptacle 154a includes 180° rear wall left outer stacking foot cross member receptacle 156a; and 180° rear wall left inner stacking foot receptacle 154b includes 180° rear wall left inner stacking foot cross member receptacle 156b. Operation of the stacking feet and the receptacles will be discussed in greater detail below for both the 0° and 180° stacking orientations.
C. Right Side Wall 6
Referring to FIGS. 1, 4, 7, and 8, right side wall 6 includes an inner surface 20 and outer surface 22. Outer surface 22 includes tag holder 26, which, according to an exemplary embodiment of the present invention, can hold a radio frequency (RF) identification (RFID) tag (not shown). RFID tags are well known to those of ordinary skill in the art, and detailed discussion of them has been omitted for the purpose of brevity. Tag holder 26 preferably comprises a recessed area from front wall outer surface 22, is substantially rectangular, and further comprises a plurality of mounting holes 27a, b. Right side wall 6 further includes top surface 24. Two pairs of stacking feet are located on both sides of right side wall 6, on outer surface 22; a first pair are located a short distance from front wall 4 and a second pair are located a short distance from rear wall 8. Located adjacent to front wall 4 of right side wall 6 are right side wall left outer stacking foot 38a, and right side wall left inner stacking foot 38b. Located adjacent to rear wall 8 of right side wall 6 are right side wall right outer stacking foot 44a, and right side wall right inner stacking foot 44b.
Each of the stacking feet comprise certain common characteristic components. Right side wall right outer stacking foot 44a comprises right side wall rear outer stacking foot flat portion 45a, right side wall rear outer stacking foot cross member 46a, and right side wall rear outer stacking foot sloped surface 47a. Right side wall right inner stacking foot 44b comprises right side wall rear inner stacking foot flat portion 45b, right side wall rear inner stacking foot cross member 46b, and right side wall rear inner stacking foot sloped surface 47b. Right side wall left outer stacking foot 38a comprises right side wall front outer stacking foot flat portion 39a, right side wall front outer stacking foot cross member 40a, and right side wall front outer stacking foot sloped surface 41a. Right side wall left inner stacking foot 38b comprises right side wall front inner stacking foot flat portion 39b, right side wall front inner stacking foot cross member 40b, and right side wall front inner stacking foot sloped surface 41b.
Furthermore, right side wall 6 comprises 180° stacking ledge 42 that sits upon upper surface 162 of left side wall 10 when upper tray 100′ is stacked in a 180° stacking orientation on lower tray 100 (as shown in FIG. 41). As can be seen in the above referenced drawings, right side wall 6, and its components, are substantially wider than conventional trays because of the significant amount of weight tray 100 is designed to carry. Right side wall 6 further comprises ventilation slots 36, to provide air flow through tray 100, especially when upper trays 100′, 100″ and so on are stacked upon lower tray 100. Right side wall 6 further includes right side wall handle 34, which includes right side wall handle opening lower 30 and right side wall handle opening upper 32. Right side wall handle opening lower 30 provides a location for a user to place the hook end of tray retrieving tool 276, as shown in FIG. 39. By incorporating similar structures on all four walls, it is much easier for users to pull tray 100 off other trays or from a tray cleaning area. Located above right side wall handle opening upper 32, on an upper surface of right side wall 6 are scalloped surfaces 28, which extend from top surface 24 of right side wall 6 to a point just above where right side wall handle opening upper 32 ends on inner surface 20 of right side wall 6, as shown in FIGS. 1, 4 and 7. Scalloped surfaces 28 provide a substantially easier means for a user to grip tray 100, and also provides a means for a user to determine, at a quick glance, which way tray 100 is oriented, because it is the only surface area of tray 100 that has that unique scallop design.
Located on inner surface 20 of right side wall 6 are receptacles for 0° and 180° stacking. Two pairs of stacking receptacles (a pair of 0° stacking receptacles, and a pair of 1800 stacking receptacles) are located on inner surface 20 on the left side of right side wall 6, and two pairs of stacking receptacles (a pair of 0° stacking receptacles, and a pair of 180° stacking receptacles) are located on inner surface 20 of the right side of right side 6. Located at the right side of right side wall 6 (as viewed from the interior of tray 100) are 0° right side wall front outer stacking foot receptacle 48a, and 0° right side wall front inner stacking foot receptacle 48b. Between 0° right side wall front outer stacking foot receptacle 48a and 0° right side wall front inner stacking foot receptacle 48b is 180° right side wall front outer stacking foot receptacle 60a, and to the left of 48b is 180° right side wall front inner stacking foot receptacle 60b (as viewed from inside tray 100). Located at the left side of right side wall 6 (as viewed from the interior of tray 100) are 0° right side wall rear outer stacking foot receptacle 52a, and 0° right side wall rear inner stacking foot receptacle 52b. Between 0° right side wall rear outer stacking foot receptacle 52a and 0° right side wall rear inner stacking foot receptacle 52b is 180° right side wall rear outer stacking foot receptacle 56a, and to the right of 0° right side wall rear inner stacking foot receptacle 52b is 180° right side wall rear inner stacking foot receptacle 56b (as viewed from inside tray 100).
As shown in FIG. 7, 0° right side wall front outer stacking foot receptacle 48a includes 0° right side wall front outer stacking foot cross member receptacle 50a; 0° right side wall front inner stacking foot receptacle 48b includes 0° right side wall front inner stacking foot cross member receptacle 50b; 180° right side wall front outer stacking foot receptacle 60a includes 180° right side wall front outer stacking foot cross member receptacle 62a; and 180° right side wall front inner stacking foot receptacle 60b includes 180° right side wall front inner stacking foot cross member receptacle 62b. Also as shown in FIG. 7, 0° right side wall rear outer stacking foot receptacle 52a includes 0° right side wall rear outer stacking foot cross member receptacle 54a; 0° right side wall rear inner stacking foot receptacle 52b includes 0° right side wall rear inner stacking foot cross member receptacle 54b; 180° right side wall rear outer stacking foot receptacle 56a includes 180° right side wall rear outer stacking foot cross member receptacle 58a; and 180° right side wall rear inner stacking foot receptacle 56b includes 180° right side wall rear inner stacking foot cross member receptacle 58b. Operation of the stacking feet and the receptacles will be discussed in greater detail below for both the 0° and 180° stacking orientations.
D. Left Side Wall 10
Referring to FIGS. 1, 6, 7, and 8, left side wall 10 includes an inner surface 158 and outer surface 160. Outer surface 22 includes tag holder 164, which, according to an exemplary embodiment of the present invention, can hold a radio frequency (RF) identification (RFID) tag (not shown). RFID tags are well known to those of ordinary skill in the art, and detailed discussion of them has been omitted for the purpose of brevity. Tag holder 164 preferably comprises a recessed area from front wall outer surface 160, is substantially rectangular, and further comprises a plurality of mounting holes 165a, b. Left side wall 10 further includes top surface 162. Two pairs of stacking feet are located on both sides of left side wall 10, on outer surface 160; a first pair located a short distance from rear wall 8 and a second pair located a short distance from front wall 4. Located to the left side of left side wall 10 are left side wall left outer stacking foot 186a, and left side wall left inner stacking foot 186b. Located to the right of left side wall 10 are left side wall right outer stacking foot 176a, and left side wall right inner stacking foot 176b.
Each of the stacking feet comprise certain common characteristic components. Left side wall right outer stacking foot 176a comprises left side wall front outer stacking foot flat portion 178a, left side wall front outer stacking foot cross member 180a, and left side wall front outer stacking foot sloped surface 182a. Left side wall right inner stacking foot 176b comprises left side wall front inner stacking foot flat portion 178b, left side wall front inner stacking foot cross member 180b, and left side wall front inner stacking foot sloped surface 182b. Left side wall rear outer stacking foot 186a comprises left side wall rear outer stacking foot flat portion 188a, left side wall rear outer stacking foot cross member 190a, and left side wall rear outer stacking foot sloped surface 192a. Left side wall rear inner stacking foot 186b comprises left side wall rear inner stacking foot flat portion 188b, left side wall rear inner stacking foot cross member 190b, and left side wall rear inner stacking foot sloped surface 192b.
Furthermore, left side wall 10 comprises 180° stacking ledge 184 that sits upon upper surface 24 of right side wall 6 when upper tray 100′ is stacked in a 180° stacking orientation on lower tray 100 (as shown in FIG. 41). As can be seen in the above referenced drawings, left side wall 10, and its components, are substantially wider than conventional trays because of the significant amount of weight tray 100 is designed to carry. Left side wall 10 further comprises ventilation slots 174, to provide air flow through tray 100, especially when upper trays 100′, 100″ and so on are stacked upon lower tray 100. Left side wall 10 further includes left side wall handle 172, which includes left side wall handle opening lower 168 and left side wall handle opening upper 170. Left side wall handle opening lower 168 provides a location for a user to place the hook end of tray retrieving tool 276, as shown in FIG. 39. By incorporating similar structures on all four walls, it is much easier for users to pull tray 100 off other trays or from a tray cleaning area.
Located on inner surface 158 of left side wall 10 are receptacles for 0° and 180° stacking. Two pairs of stacking receptacles (a pair of 0° stacking receptacles, and a pair of 180° stacking receptacles) are located on inner surface 158 on the left side of left side wall 10, and two pairs of stacking receptacles (a pair of 0° stacking receptacles, and a pair of 180° stacking receptacles) are located on inner surface 158 of the right side of left side wall 10. Located adjacent to rear wall 8 of left side wall 10 (as viewed from the interior of tray 100) are 180° left side wall rear outer stacking foot receptacle 206a, and 180° left side wall rear inner stacking foot receptacle 206b. Between 180° left side wall rear outer stacking foot receptacle 206a and 180° left side wall rear inner stacking foot receptacle 206b is 0° left side wall rear outer stacking foot receptacle 198a, and to the left of 180° left side wall rear inner stacking foot receptacle 206b is 0° left side wall rear inner stacking foot receptacle l98b (as viewed from inside tray 100). Located adjacent to front wall 4 of left side wall 10 (as viewed from the interior of tray 100) are 180° left side wall front outer stacking foot receptacle 202a, and 180° left side wall front inner stacking foot receptacle 202b. Between 180° left side wall front outer stacking foot receptacle 202a and 180° left side wall front inner stacking foot receptacle 202b is 0° left side wall front outer stacking foot receptacle 194a, and to the right of 180° left side wall front inner stacking foot receptacle 202b is 0° left side wall front inner stacking foot receptacle 194b (as viewed from inside tray 100).
As shown in FIG. 7, 180° left side wall rear outer stacking foot receptacle 206a includes 180° left side wall rear outer stacking foot cross member receptacle 208a; 180° left side wall rear inner stacking foot receptacle 206b includes 180° left side wall rear inner stacking foot cross member receptacle 208b; 0° left side wall rear outer stacking foot receptacle 198a includes 0° left side wall rear outer stacking foot cross member receptacle 200a; and 0° left side wall rear inner stacking foot receptacle 198b includes 0° left side wall rear inner stacking foot cross member receptacle 200b. Also as shown in FIG. 7, 180° left side wall front outer stacking foot receptacle 202a includes 180° left side wall front outer stacking foot cross member receptacle 204a; 180° left side wall front inner stacking foot receptacle 202b includes 180° left side wall front inner stacking foot cross member receptacle 204b; 0° left side wall front outer stacking foot receptacle 194a includes 0° left side wall front outer stacking foot cross member receptacle 196a; and 0° left side wall front inner stacking foot receptacle 194b includes 0° left side wall front inner stacking foot cross member receptacle 196b. Operation of the stacking feet and the receptacles will be discussed in greater detail below for both the 0° and 180° stacking orientations.
E. Base 2
Reference is made to FIGS. 1, 2, 7, and 8 for a description of base 2. As shown in FIGS. 1, 2, 7, and 8, base 2 comprises an essentially uniform solid base, but further includes several drain holes 16 alongside front wall 4, right side wall 6, rear wall 8 and left side wall 10. Base 2 further includes center drain hole 17. Base 2 includes an upper surface 12, and a lower surface 14. Further, lower surface 14 of base 2 includes a plurality of ribs to form a substantially strong base structure, for carrying additional weight due to the type of baked products to be carried in tray 100. According to an exemplary embodiment of the present invention, base 2 further comprises a plurality of drain channels, 18a-d, which are described in greater detail below. Drain channels 18a-d provide a mechanism to drain water following washing of tray 100. According to an exemplary embodiment of the present invention, base 2 still further includes a plurality of left side spacer holes 214a-c, and right side spacer holes 216a-c. Preferably, spacer holes 214, 216 provide means to retain optional left and right spacers 210, 212 that can be used to change the interior dimensions of tray 100 to carry different types of product. Spacers 210, 212 will be described in greater detail below.
F. Spacers 210212
Referring to FIGS. 26-35, left and right spacers 210, 212 are illustrated in tray 100 according to an embodiment of the present invention. FIG. 26 is a top isometric view of the tray shown in FIG. 1 illustrating a plurality of spacers to contain different types of products substantially motion-free within tray 100 according to an additional embodiment of the invention; FIG. 27 is a top view of the tray shown in FIGS. 1 and 26; FIG. 28 is a front view of the spacer shown in FIG. 26, for use in the tray shown in FIGS. 1 and 9, to contain different types of products substantially motion-free according to an additional embodiment of the invention; FIG. 29 is a right side view of the spacer shown in FIG. 26; FIG. 30 is rear view of the spacer shown in FIG. 26; FIG. 31 is a left side view of the spacer shown in FIG. 26; FIG. 32 is a top perspective view of the spacer shown in FIG. 26; FIG. 33 is a bottom perspective view of the spacer shown in FIG. 26; FIG. 34 is a cross sectional view of the spacer shown in FIG. 26, along line B-B shown in FIG. 28 illustrating a hole and a sloped surface of a stiffener of the spacer; and FIG. 35 is a cross sectional view of the spacer shown in FIG. 26, along line A-A shown in FIG. 28 illustrating an internal portion of the stiffener of the spacer.
Spacers 210, 212 provide a means for users to change the interior dimensions of tray 100 so that it can be adapted to carry different types of products. Although FIGS. 26 and 27 illustrate both left spacer 210, and right spacer 212 in tray 100, this need not be the case as one of ordinary skill in the art of the present invention can appreciate. For example, only one of the spacers can be utilized if that provides the best fit for a certain type of product.
Spacers 210, 212 comprise a single piece of molded plastic, manufactured from the same or similar materials as tray 100. Spacers 210, 212 can further optionally include glossy free surfaces 278 as disuse above. Referring to FIGS. 28-35, spacers 210, 212 each comprise a plurality of spacer plugs 220a-c that fit within spacer holes 214, 216 as shown in FIGS. 7, 26 and 27. As one of ordinary skill in the art of the present invention can appreciate, for each spacer there is only one way the spacer can fit within spacer holes 214, 216 because of the spacing between the holes 214, 216 and the corresponding spacing of spacer plugs 220. Manufacturing spacers 210, 212 such that they can only be located within tray 100 in one orientation prevents a user from inadvertently placing spacers 210, 212 in tray 100 incorrectly (i.e., with spacer wall side facing the baked product, thereby damaging it). Spacers 210, 212 have a substantially vertical planar product side 226, which preferably faces the baked product being carried in tray 100. Spacers 210, 212 have several features that provide additional strength for retaining baked products within tray 100. Spacer stiffeners 222a-c, which can be seen in greater detail in FIGS. 29-35, provide a significant amount of strength to spacers 210, 212. As shown in FIG. 29, spacer stiffener 222d comprises a relatively thicker lower portion formed at an angle θ1 that is between about 25° and about 35°. According to a preferred embodiment of the present invention, θ1 is about 30°. Spacer stiffener 22d also comprises a relatively narrower upper portion that is formed at an angle θ2 between about 10° and 20°. According to a preferred embodiment of the present invention, θ2 is about 15°. As those of ordinary skill in the art of the present invention can appreciate, however, spacers 210, 212 can be shaped differently, yet still function as effectively. For example, the particular shape shown in FIG. 29 optimizes the strength of spacers 210, 212, yet minimizes the amount of plastic used in manufacturing spacer s210, 212.
Referring to FIGS. 29-35 in general, but especially FIG. 34, which is a cross sectional view along lines B-B as shown in FIG. 28, spacer vent 218 is shown, which also provides stiffness and strength to spacers. Spacer vents 218 allow air to flow through spacers 210, 212 and are substantially rectangular in shape, with substantially circular ends (at the narrow ends). According to an exemplary embodiment of the present invention, spacer vents 218 further include a ribbed edge that provides additional stiffness and strength to spacers 210, 212. Use of spacers 210, 212 is discussed in greater detail below.
G. Glossy Free Surfaces 278
The glossy free surfaces 278, as briefly described above, can include a plurality of micro-bumps, diamond etching, recesses, ribs, grooves, and various other types of markings, indentations and other alterations (micro-bumps) 279a-f of the surfaces of tray 100. Micro-bumps 279a-f are raised or depressed areas on various surfaces of tray 100 that can also assist in preventing commonly used stickers from adhering permanently to the surfaces of tray 100, as one of ordinary skill in the art can appreciate. These stickers can indicate, for example, the time and date of processing, the type of product, the source of the product, the plant that baked and/or packed the product, and other such information that might be necessary. Once the product is retrieved from tray 100, the stickers are no longer pertinent, and must be removed. Micro-bumps 279a-f make such removal much easier, because there is less surface area of tray 100 for the sticker to adhere to. Because of micro-bumps 279a-f, only about 30% to about 40% of the sticker surface area adheres to tray 100. On a substantially flat tray surface, however, close to about 100% of the surface area of the sticker adheres to the substantially flat tray surface.
Examples of different types of micro-bumps 279a-f are shown in FIGS. 36A-F. Micro-bumps 279a-f can be in almost any imaginable shape, though, as FIGS. 36A-F illustrate, there are more common designs prevalent throughout the industry. As shown in FIG. 36A, micro-bumps 279a are in the form of an “X”; in FIG. 36B, micro-bumps 279b are in the form of and circles ∘; in FIG. 36C, micro-bumps 279c are in the form of a box □; in FIG. 36D, micro-bumps 279d are in the form of a diamond ⋄; in FIG. 36E, micro-bumps 279e are in the form of a triangle ▴; and in FIG. 36F, micro-bumps 279f are in the form of dots ![]()
. According to another embodiment of the present invention, the micro-bumps 279a-f can be in the shape of alternating grooves or ridges that can be curved (elliptical, circular, oval, “s” shaped, among others) or substantially straight. As those of ordinary skill in the art of the present invention can appreciate, glossy free surfaces can be located on nearly any surface portion of tray 100.
III. Stacking
A. 0° Stacking Configuration
FIG. 40 is a front isometric view of the two trays shown in FIG. 1 in a 0° stacking orientation according to an embodiment of the present invention. As shown in FIG. 40, and referring also to FIGS. 1-8, and the descriptions of each provided above, upper tray 100′ is stacked upon lower tray 100 in a 0° stacking orientation. According to a preferred embodiment of the present invention, in the 0° stacking orientation, there is about 4.75″ clearance between the lower surface 14′ of base 2′ of upper tray 100′, and upper surface 12 of base 2 of lower tray 100. As those of ordinary skill in the art of the present invention can appreciate, however, the clearance between the lower surface 14′ of base 2′ of upper tray 100′, and upper surface 12 of base 2 of lower tray 100 can be designed to be any practical value. The clearance value in the 0° stacking configuration will be determined by the type of products stored and shipped by tray 100, which, according to a preferred embodiment of the present invention, is baked goods. As discussed above, when trays 100, 100′ are stacked in the 0° stacking orientation, they normally can carry the maximum amount of weight of the two stacking orientations because of the clearances between lower surface 14 of base 2′ of upper tray 100′, and upper surface 12 of lower tray 100. Because trays 100, 100′ can carry a significant amount of weight, they have been designed to be exceptionally sturdy in all stacking orientations, but especially in the 0° stacking orientation according to a preferred embodiment of the present invention. It is for this reason that the above described features of the stacking feet and stacking receptacle have been incorporated. In the discussion below, reference shall be made only to the interface between front wall 4′ of upper tray 100′ and front wall 4 of lower tray 100, and the interface between right side wall 6′ of upper tray 100′ and right side wall 6 of lower tray 100, with the understanding, as can be appreciated by those of ordinary skill in the art of the present invention, that the interface between rear wall 8′ of upper tray 100′ and rear wall 8 of lower tray 100 is substantially similar to that of the front walls of upper and lower rays 100′, 100, and likewise applies to the interface between left side wall 6′ of upper tray 100′ and left side wall 6 of lower tray 100. The discussion of the latter two sets of walls has been omitted for the purpose of brevity. The same shall apply to the discussion below of the 180° stacking orientation.
To stack upper tray 100′ onto lower tray 100 in the 0° stacking orientation, the user simply places upper tray 100′ tray over and then onto lower tray 100. The same operation applies for un-stacking trays, although tray retrieval tool, as discussed above, can be used whenever un-stacking is desired, especially when trays 100 are retrieved from hot water baths to clean and sterilize them.
In the 0° stacking orientation, front wall 4′ of upper tray 100 is aligned with front wall 4 of lower tray 100, right side wall 6′ of upper tray 100′ is aligned with right side wall 6 of lower tray 100, and so on. As shown in FIGS. 3, 7, 8, and 40, and in reference to front walls 4′ and 4 of the upper and lower trays 100′ 100, respectively, in the 0° stacking orientation, front wall left outer stacking foot 76a′ is received within 0° front wall left outer stacking foot receptacle 94a, front wall left inner stacking foot 76b′ is received within 0° front wall left inner stacking foot receptacle 94b, front wall right outer stacking foot 86a′ is received within 0° front wall right outer stacking foot receptacle 98a, and front wall right inner stacking foot 86b′ is received within 0° front wall right inner stacking foot receptacle 98b. According to a preferred embodiment of the present invention, front wall left outer stacking foot flat portion 78a′ rests upon a substantially horizontal flat surface formed within 0° front wall left outer stacking foot receptacle 94a, and front wall left outer stacking foot cross member 80a′ fits within 0° front wall left outer stacking foot cross member receptacle 96a of 0° front wall left outer stacking foot receptacle 94a.
Attention is directed towards FIG. 42, which is a cross sectional view along line A-A shown in FIG. 7 and line B-B shown in FIG. 8, illustrating location and interaction between front wall left outer stacking foot cross member 80a′ of a front wall left outer stacking foot 76a′ of upper tray 100 and 0° front wall left outer stacking foot cross member receptacle 94a of lower tray 100, when trays 100′, 100 are stacked in a 0° stacking orientation, according to an embodiment of the present invention. As shown in FIG. 41, according to an exemplary embodiment of the present invention, front wall left outer stacking foot 76a′ of upper tray 100′ sits within 0° front wall left outer stacking foot receptacle 94a of lower tray 100. Front wall left outer stacking foot 76a′ rests upon the substantially horizontal lower portion of 0° front wall left outer stacking foot receptacle 94a. Front wall left outer stacking foot cross member 80a′ fits within and interfaces with a slot in 0° front wall left outer stacking foot cross member receptacle 96a of lower tray 100. Those of ordinary skill in the art of the present invention can appreciate that because front wall left outer stacking foot cross member 80a′ is restrained by the slot of 0° front wall left outer stacking foot cross member receptacle 96a, side-to-side motion, as represented by line A in FIG. 42, is substantially restricted. Further. because there are four such stacking feet on each wall of tray 100, for both the 0° and 180° stacking orientations, side-to-side motion is substantially restricted in all directions. Similarly, the other stacking feet components 76b′, 86a′, and 86b′ of front wall 4′ of upper tray 100′ interface in a similar manner with receptacle components 94b, 98a, and 98b, of lower tray 100.
According to a preferred embodiment of the present invention, by locating and interfacing front wall left outer stacking foot cross member 80a′ within 0° front wall left outer stacking foot cross member receptacle 96a of 0° front wall left outer stacking foot receptacle 94a (and having the same happen for all sixteen stacking feet and receptacles), upper tray 100′ is substantially secured to lower tray 100 in the 0° stacking orientation, and side-to-side, front-wards and backwards motions are substantially reduced or eliminated according to an exemplary embodiment of the present invention. Further, greater amounts of weight can be carried by trays 100 because all the walls are substantially vertical, and substantially all the weight carried by trays 100 is substantially directly transferred to lower trays 100 and the surface upon which the lowest tray 100 is sitting upon. A substantially small portion of the weight of the tray 100 and baked goods is transferred to a horizontal component, thereby making trays 100 extremely efficient in terms of their weight carrying capacity and structure.
The front wall left outer stacking foot cross member 80a, as well as all the other cross members for all the other stacking feet (86a, 86b, 76a, 76b, 38a, 38b, 44a, 44b, 134a, 134b, 124a, 124b, 186a, 186b, 176a, and 176b) will retain their respective stacking foot flat portions (88a, 88b, 78a, 78b, 39a, 39b, 45a, 45b, 136a, 136b, 126a, 126b, 188a, 188b, 178a, 178b) in the event tray 100 is hit by a large object or force, and breakage about the stacking feet occurs. If the cross members were not there, then if the stacking foot flat portion was separated from the rest of the stacking foot, the trays would not be as sturdy, and would not be able to stack as much baked product, and would not function properly in the event of such breakage.
As shown in FIGS. 4, 7, 8, and 40, and in reference to right side walls 6′ and 6 of the upper and lower trays 100′ 100, respectively, in the 0° stacking orientation, right side wall front outer stacking foot 38a′ is received within 0° right side wall front outer stacking foot receptacle 48a, right side wall front inner stacking foot 38b′ is received within 0O right side wall front inner stacking foot receptacle 48b, right side wall rear outer stacking foot 44a′ is received within 0° right side wall rear outer stacking foot receptacle 52a, and right side wall rear inner stacking foot 44b′ is received within 0° right side wall rear inner stacking foot receptacle 52b. Right side wall front outer stacking foot flat portion 39a′ of right side wall front outer stacking foot 38a′ rests upon a substantially horizontal flat surface formed within 0° right side wall front outer stacking foot receptacle 48a, and right side wall front outer stacking foot cross member 40a′ fits within 0° right side wall front outer stacking foot cross member receptacle 50a of 0° right side wall front outer stacking foot receptacle 48a. Similarly, the other stacking feet components 38b′, 44a′, and 44b′ of right side wall 6′ of upper tray 100′ interface in a similar manner with receptacle components 60b, 52a, and 52b, of lower tray 100.
According to a preferred embodiment of the present invention, by locating and interfacing right side wall front outer stacking foot cross member 40a′ within 0° right side wall front outer stacking foot cross member receptacle 50a of 0° front side wall front outer stacking foot receptacle 48a, upper tray 100′ is substantially secured to lower tray 100 in the 0° stacking orientation, and side-to-side, front-wards and backwards motions are substantially reduced or eliminated according to an exemplary embodiment of the present invention.
As discussed above, the stacking feet 124a, b′ and 134a, b′ of rear wall 8′ of upper tray 100′ interface with the 0° stacking receptacle 142a, b and 146a, b of lower tray 100 in a similar manner as above with respect to front wall 4′ of upper tray 100′ and front wall 4 of lower tray 100. Furthermore, the stacking feet 176a, b′ and 186a, b′ of left side wall 10′ of upper tray 100′ interface with the 0° stacking receptacle 198a, b and 202a, b of left side wall 10 of lower tray 100 as described above with respect to right side wall 6′ of upper tray 100′ and right side wall 6 of lower tray 100.
B. 180° Stacking
FIG. 41 is a front isometric view of the two trays shown in FIG. 1 in a 180° stacking orientation according to an embodiment of the present invention. As shown in FIG. 41, and referring also to FIGS. 1-8, and the description of each above, upper tray 100′ is stacked upon lower tray 100 in a 180° stacking orientation. According to a preferred embodiment of the present invention, in the 180° stacking orientation, there is about 3.25″ clearance between the lower surface 14′ of base 2′ of upper tray 100, and upper surface 12 of base 2 of lower tray 100. As those of ordinary skill in the art of the present invention can appreciate, however, the clearance between the lower surface 14′ of base 2′ of upper tray 100′, and upper surface 12 of base 2 of lower tray 100 can be designed to be any practical value. The clearance value in the 180° stacking configuration will be determined by the type of products stored and shipped by tray 100, which, according to a preferred embodiment of the present invention, is baked goods. As discussed above, trays 100, 100′, when stacked in the 180° stacking orientation, can still carry a significant amount of weight. In the discussion below, reference shall be made only to the interface between front wall 4′ of upper tray 100′ and rear wall 8 of lower tray 100, and the interface between right side wall 6′ of upper tray 100′ and left side wall 10 of lower tray 100, with the understanding, as can be appreciated by those of ordinary skill in the art of the present invention, that the interfaces between rear wall 8′ of upper tray 100′ and front wall 4 of lower tray 100 is substantially similar to that of the front wall 4′ and rear wall 8 of upper and lower rays 100′, 100, and likewise applies to the interface between left side wall 10′ of upper tray 100′ and right side wall 6 of lower tray 100. The discussion of the latter two sets of walls has been omitted for the purpose of brevity.
To stack upper tray 100′ onto lower tray 100 in the 180° stacking orientation, the user simply places upper tray 100′ tray over and then onto lower tray 100. The same operation applies for un-stacking trays, although tray retrieval tool 276, as discussed above, can be used whenever un-stacking is desired, especially when trays 100 are retrieved from hot water baths to clean and sterilize them.
In the 180° stacking orientation, as shown in FIG. 41, and in reference to FIGS. 3, 5, 7, and 8, front wall 4′ of upper tray 100 is aligned with rear wall 8 of lower tray 100, right side wall 6′ of upper tray 100′ is aligned with left side wall 10 of lower tray 100, and so on. In the 180° stacking orientation, front wall left outer stacking foot 76a′ is received within 180° rear wall right outer stacking foot receptacle 150a, front wall left inner stacking foot 76b′ is received within 180° rear wall right inner stacking foot receptacle 150b, front wall right outer stacking foot 86a′ is received within 180° rear wall left outer stacking foot receptacle 154a, and front wall right inner stacking foot 86b′ is received within 180° rear wall left inner stacking foot receptacle 154b. Front wall left outer stacking foot flat portion 78a′ of front wall left outer stacking foot 76a′ rests upon a substantially horizontal flat surface formed within 180° rear wall right outer stacking foot receptacle 150a, and front wall left outer stacking foot cross member 80a′ fits within 180° rear wall right outer stacking foot cross member receptacle 152a of 180° rear wall right outer stacking foot receptacle 150a.
Those of ordinary skill in the art of the present invention can appreciate that because of the similarities between the 0° and 180° stacking receptacles, a detailed description of the interface between the stacking feet and the 180° stacking receptacles is not necessary, and has been omitted for the purpose of brevity. The illustration shown in FIG. 42 applies equally well for the corresponding components in the 180° stacking orientation. Certain dimensions are different as well. The interface and functioning of the stacking and receptacle components in the 180° stacking orientation is substantially identical to the interface and functioning of the stacking and receptacle components in the 0° stacking orientation according to an exemplary embodiment of the present invention.
By fitting front wall left outer stacking foot cross member 80a′ within 180° rear wall right outer stacking foot cross member receptacle 152a of 180° rear wall right outer stacking foot receptacle 150a (and having the same happen for all sixteen stacking feet and corresponding 180° stacking receptacle), upper tray 100′ is substantially secured to lower tray 100, and side-to-side, front-wards and backwards motions are substantially reduced or eliminated.
In the 180° stacking orientation as shown in FIG. 41, and referring again to FIGS. 4, 6, 7, and 8, right side wall front outer stacking foot 38a′ is received within 180° left side wall rear outer stacking foot receptacle 206a, right side wall front inner stacking foot 38b′ is received within 180° left side wall rear inner stacking foot receptacle 206b, right side wall rear outer stacking foot 44a′ is received within 180° left side wall front outer stacking foot receptacle 202a, and right side wall rear inner stacking foot 44b′ is received within 180° left side wall front inner stacking foot receptacle 202b. Right side wall front outer stacking foot flat portion 39a′ of right side wall front outer stacking foot 38a′ rests upon a substantially horizontal flat surface formed within 180° left side wall rear outer stacking foot receptacle 206a, and right side wall front outer stacking foot cross member 40a′ fits within 180° left side wall rear outer stacking foot cross member receptacle 208a of 180° left side wall rear outer stacking foot receptacle 206a.
Similarly, the same components of the other stacking feet for right side wall 6′ interface with the corresponding components for left side wall 10, as does the stacking feet and stacking feet receptacles for rear wall 8′ and front wall 4, and left side wall 10′ and right side wall 6. Further more, right side wall 180° stacking ledge 42 rests upon left side wall top surface 162, rear wall stacking 180° ledge 132 rests upon front wall top surface 70, left side wall stacking 180° ledge 184 rests upon right side top surface 24, and front wall stacking 180° ledge 84 rests upon rear wall top surface 118.
IV. Use of Spacers
In use, spacers 210, 212 are simply inserted in either or both sided of tray 100, with spacer product side 226 facing an interior portion of tray 100. One or two spacers 210, 212 can be used according to a preferred embodiment of the invention. According to alternative embodiments of the present invention, spacers 210, 212 can be provide for front wall 4 and rear wall 8, and along a plurality of lines formed by spacer holes. For example, a series of spacer holes can be formed on or about a centerline of tray 100 extending from front wall 4 to rear wall 8 effectively cutting the storage space of tray 100 by about one-half. Although not shown in the accompanying drawings, those of ordinary skill in the art can appreciate that three, for or even more spacers can be used in a single tray 100, with a multitude of spacer hole configurations to allow storage and transport of many different types of products in tray 100, all of which are considered to be within the scope of the present invention.
V. Draining Water
Referring to FIGS. 1, 2, 7, 37, and 38, draining of water via drain channels 18a-d will be discussed. According to a preferred embodiment of the present invention, tray 100 comprises four drain channels 18a-d as shown in FIG. 37. As those of ordinary skill in the art of the present invention can appreciate, however, tray 100 need not be exclusively limited to four drain channels, as more or less drain channels 18 can be accommodated within base 2. As shown in FIG. 37, first drain channel 18a includes a centerline 228, a first upper surface 230, a second upper surface 232, a first sloped surface 234 and a second sloped surface 236. Drain channels 18b-d are similarly fabricated. Separating first drain channel 18a from second drain channel 18b is first drain interface surface 268; separating second drain channel 18b from third drain channel 18c is second drain interface surface 270; separating third drain channel 18c from fourth drain channel 18d is third drain interface surface 272; and separating fourth drain channel 18d from first drain channel 18a is fourth drain interface surface 274.
According to preferred embodiment of the present invention, each drain channel 18a-d is substantially similar in dimensions, and are substantially equally angularly spaced about upper surface 12 of base 2 (in a star shaped pattern), although this need not be the case, as those of ordinary skill in the art can appreciate. According to an exemplary embodiment of the present invention, spread angle θ1, as shown in FIG. 37, is the spread angle of each of the drain channels 18a-d, and can range from about 13.5° to about 15.5°. According to a preferred embodiment of the present invention, angle θ1 is about 14.6°. Referring to FIG. 38, which is a cross section view of base 2 of tray 100 along sectional line A-A shown in FIG. 37, drain angle θ2 ranges between about 0.10° and about 0.40Y°. According to a preferred embodiment of the present invention, drain angle θ2 is about 0.25°. According to a preferred embodiment of the present invention, each drain channel has a drain angle that is substantially similar. Height h1, which shows the maximum depth of drain channels 18a-d at center drain hole 17, ranges between about 0.050″ to about 0.070″, and according to a preferred embodiment of the present invention, height h1 is about 0.060″. Further, as shown in FIG. 37 and 38, lines 268, 270, 272, 274 also are formed at an angle from upper surface 12 of base 2, to center hole 17. This angle, θ3, is between about 1° and 3°, and according to a preferred embodiment of the present invention, θ3 is about 1.5°.
Following use (i.e., storage and transporting of baked product), trays 100 are washed in a high temperature, high pressure washer. Even though the plastic that trays 100 are made from naturally beads water, it is still advantageous to have the water left over from the washing process removed from trays 100 as quickly as possible. Drain channels 18a-d facilitate the water removal process by channeling water contained in the substantially flat, sold base 2 to center drain hole 17, whereby the water can be removed from trays 100. While drain channels 18a-d function effectively to drain water from trays 100, they must substantially eliminate or reduce the possibility of marking baked product after it is baked and placed in trays 100. Because drain channels are made with such slight angles, they effectively reduce or eliminate the possibility of marking the baked product, especially tortillas.
VI. Tray 300
An alternative embodiment of tray 100 is shown in FIGS. 9-25. Tray 300, is shown and discussed in reference to FIGS. 9-25, is substantially similar in design and functionality as tray 100, and so a detailed description of tray 300 will not be provided, for the purpose of brevity. Tray 300 does not include front wall hook area 68 nor rear wall hook area 116. Otherwise, tray 300 retains substantially similar stacking features in both the 0° and 180° stacking orientations, water draining capabilities via drain channels 18a-d, scalloped surface 28, and right side wall handle 34 and left side wall handle 172. Further, tray 300 can utilize spacers 210, 212, as discussed above in regard to tray 100.
The present invention has been described with reference to certain exemplary embodiments thereof. However, it will be readily apparent to those skilled in the art that it is possible to embody the invention in specific forms other than those of the exemplary embodiments described above. This may be done without departing from the spirit and scope of the invention. The exemplary embodiments are merely illustrative and should not be considered restrictive in any way. The scope of the invention is defined by the appended claims and their equivalents, rather than by the preceding description.
All United States patents and applications, foreign patents, and publications discussed above are hereby incorporated herein by reference in their entireties.
Patent Application
20080023426
