TRAY

Abstract

A tray includes a plurality of elongated pockets, such as for receiving raw bread dough therein. In one embodiment, the pockets are defined by a lower wall and adjacent side walls, and the lower walls and side walls are spaced away from a base wall of the tray.

Description

This application claims priority to U.S. Provisional Application Ser. No. 60/867,051, filed Nov. 21, 2006.

BACKGROUND OF THE INVENTION

The present invention relates generally to a tray, which can be used for transporting and storing items, including food items such as raw bread dough.

Currently, some restaurants featuring freshly-baked bread ship frozen raw bread dough from central locations to each of the stores in disposable cardboard trays. In the store, the trays of frozen bread dough are placed on metal sheets that are supported in a large rack where the dough is thawed and allowed to rise. The risen dough is then removed from the trays and placed in ovens for baking. The cardboard trays cannot be reused and are therefore discarded, which is costly and environmentally undesirable.

SUMMARY OF THE INVENTION

A molded plastic tray includes a plurality of elongated pockets, such as for receiving raw bread dough therein.

In one embodiment, the pockets are defined by a lower wall and adjacent side walls, and the lower walls and side walls are spaced away from a base wall of the tray. The tray may be rotomolded or twin sheet thermoformed. The rotomolding process creates a tray that is free of hard edges, crevices or corners, which makes the tray easy to clean and reuse for food items. Alternatively, the tray could be twin sheet thermoformed.

In another embodiment, the pockets and dividers are molded in a single thermoformed sheet.

In use, the raw bread dough is shipped to the stores in the trays. At the stores, the trays support themselves in a rack for thawing and rising, or can alternatively be placed on the metal sheets currently used. After rising, the raw dough is removed from the trays and baked. The empty trays are then returned to the central location where they are washed and reused.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a tray according to a first embodiment of the present invention.

FIG. 2 is a top view of the tray of FIG. 1.

FIG. 3 is a side view of the tray of FIG. 1.

FIG. 4 is a section view taken along line A-A of FIG. 2.

FIG. 5 is an end view of the tray of FIG. 1.

FIG. 6 is a section view taken along line B-B of FIG. 2.

FIG. 7 is a perspective view of the tray of FIG. 1 with a similar tray stacked thereon.

FIG. 8 is a side view of the trays of FIG. 7.

FIG. 9 is a section view through the trays of FIG. 8.

FIG. 10 is an end view of the trays of FIG. 8.

FIG. 11 is a section view through the trays of FIG. 10.

FIG. 12 is a perspective view of a tray according to a second embodiment of the present invention.

FIG. 13 is a top view of the tray of FIG. 12.

FIG. 14 is a side view of the tray of FIG. 12.

FIG. 15 is a section view taken along line B-B of FIG. 13.

FIG. 16 is an end view of the tray of FIG. 12.

FIG. 17 is a section view taken along line A-A of FIG. 13.

FIG. 18 is a perspective view of the tray of FIG. 12 with a similar tray stacked thereon.

FIG. 19 is a side view of the trays of FIG. 18.

FIG. 20 is a section view through the trays of FIG. 18.

FIG. 21 is an end view of the trays of FIG. 18.

FIG. 22 is a section view through the trays of FIG. 18.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A tray 10 according to one embodiment of the present invention is shown in FIGS. 1-11. Referring to FIGS. 1 and 2, the tray 10 includes a base 12 and a plurality of pockets 14 opening upwardly. A pair of spaced apart longitudinal walls 16 extend upwardly from opposite sides of the base 12 and partially define the pockets 14. Dividers 18 extend perpendicularly to the longitudinal walls 16 to separate and further define the plurality of pockets 14. A lip 20 protrudes outwardly from the periphery of the base, as can more clearly be seen in FIG. 3.

FIG. 4 is a section view taken along line A-A of FIG. 2. As shown in FIG. 4, the tray 10 is generally hollow, in that the base 12 is spaced below the pockets 14. The base 12 includes a plurality of elongated recesses or channels 22 generally aligned with the dividers 18. The dividers 18 each include spaced apart side walls 24 and an upper wall 26. Each pocket 14 is defined by adjacent side walls 24 and a lower wall 28.

FIG. 5 is an end view of the tray 10. FIG. 6 is a section view through line B-B of FIG. 2. Referring to FIG. 6, the longitudinal walls 16 include end walls 30 partially defining the pockets 14. An elongated recess or channel 32 is formed in the base 12 in alignment with the longitudinal walls 16.

Referring to FIGS. 7 and 8, a similar tray 10′ can be stacked on the tray 10. Although only two stacked trays 10, 10′ are shown empty, many similar trays 10, 10′ can be loaded with items such as raw bread dough and stacked for storage, freezing, shipping, thawing and rising.

As shown in FIG. 9, the dividers 18 of the lower tray 10 are received in the channels 22′ of the upper tray 10′ to support the upper tray 10′ without contacting the contents of the pockets 14 of the lower tray 10. Referring to FIGS. 10 and 11, the longitudinal walls 16 are also received in the channel 32′ to further support the upper tray 10′. Again, numerous additional similar trays could be stacked on the upper tray 10′.

The tray 10 of the embodiment illustrated is made by rotomolding a polymer, such as polypropylene or polyethylene or other suitable materials in a suitable rotomold. The rotomolding process creates a tray 10 that is free of hard edges, crevices or corners, which makes the tray 10 easy to clean and reuse for food items. Alternatively, the tray 10 could be twin sheet thermoformed.

In use, the raw bread dough is shipped to the stores in the trays 10. At the stores, the trays 10 support themselves in a rack for thawing and rising, or can alternatively be placed on the metal sheets currently used. After rising, the raw dough is removed from the trays 10 and baked. The empty trays 10 are then returned to the central location where they are washed and reused.

A tray 110 according to another embodiment of the present invention is shown in FIGS. 12-22. Referring to FIGS. 12 and 13, the tray 110 includes a plurality of pockets 114 opening upwardly and separated by dividers 118. Each pocket 114 is defined by a lower wall 128, side walls 124 and end walls 130. A lip 120 protrudes outwardly from the periphery of the tray 110, as can be seen in FIG. 14.

FIG. 15 is a section view through the tray 110 taken along line B-B of FIG. 13. Each pocket 114 is defined between side walls 124, a pair of end walls 130 (only one shown) and a lower wall 128. The dividers 118 each comprise two of the side walls 124 and an upper wall 125 connecting the adjacent side walls 124.

Referring to FIG. 15, the tray 110 is a single thermoformed sheet. The tray 110 is substantially free from hard edges, crevices or corners and can therefore be easily cleaned for reuse for food items. Alternatively, the tray 110 could be twin sheet thermoformed.

FIG. 16 is an end view of the tray 110. FIG. 17 is a section view taken along A-A of FIG. 13. As shown, the pocket 114 is defined between the end walls 130, the lower wall 128 and the side walls 124 (one shown).

FIG. 18 illustrates the tray 110 with a similar tray 110′ nested therein. When empty, the tray 110′ can fit substantially within the pockets 114 of the lower tray 110 to reduce stacking height for return to the central location. As shown in FIG. 19, the overall stacking height of the trays 110, 110′ is reduced. FIG. 20 is a section view through the stacked trays 110, 110′. As shown, the side walls 124′ and end walls 130′ fit substantially within the pockets 114 of the lower tray 110.

FIG. 21 is an end view of the stacked trays 110, 110′. FIG. 22 is a section view through the dividers 118, 118′ of the stacked trays 110, 110′.

In use, the raw bread dough is shipped to the stores in the trays 110. At the stores, the trays 110 support themselves in a rack for thawing and rising, or can alternatively be placed on the metal sheets currently used. After rising, the raw dough is removed from the trays 110 and baked. The empty trays 110 are then returned to the central location where they are washed and reused.

In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.

Claims

1. A molded plastic tray comprising:

a base; and

a plurality of elongated, parallel pockets defined above the base.

2. The tray of claim 1 further including a pair of longitudinal walls and a plurality of dividers extending transversely between the longitudinal walls to define the pockets.

3. The tray of claim 2 wherein the dividers each include a pair of spaced-apart side walls each partially defining an adjacent one of the plurality of pockets.

4. The tray of claim 3 wherein the base includes a base wall and wherein each of the plurality of pockets includes a lower wall spaced upwardly from the base wall.

5. The tray of claim 4 wherein the side walls are spaced upwardly from the base wall.

6. The tray of claim 2 wherein the base includes a base wall and wherein each of the plurality of pockets includes a lower wall spaced upwardly from the base wall.

7. The tray of claim 6 wherein the base wall includes a plurality of elongated recesses generally aligned with the dividers, such that dividers of a similar tray stacked below would be received in the recesses.

8. The tray of claim 1 further including a lip protruding from a periphery of the tray.

9. The tray of claim 1 wherein the tray is rotomolded.

10. A thermoformed tray having a plurality of elongated, parallel pockets defined therein.

11. The tray of claim 9 wherein each of the plurality of pockets includes a lower wall, a pair of spaced apart side walls and a pair of spaced apart end walls.

12. The tray of claim 11 further including a plurality of dividers, each between a pair of adjacent ones of the plurality of pockets, each divider including a pair of the plurality of side walls.

13. The tray of claim 12 wherein each of the dividers further includes an upper wall connecting upper edges of the pair of side walls.

14. The tray of claim 13 further including a lip protruding from a periphery of the tray.

15. A molded plastic tray comprising:

a base wall;

a plurality of elongated, parallel pockets each having a lower wall spaced above the base wall;

a pair of longitudinal walls, the pockets between the longitudinal walls; and

a plurality of dividers extending transversely between the longitudinal walls, each of the dividers including a pair of spaced-apart side walls, the plurality of pockets defined between side walls of the plurality of dividers.

16. The tray of claim 15 wherein the base wall includes a plurality of elongated recesses generally aligned with the dividers, such that dividers of a similar tray stacked below would be received in the recesses.

17. The tray of claim 16 further including a lip protruding from a periphery of the tray.

18. The tray of claim 17 wherein the tray is rotomolded.

19. The tray of claim 15 wherein the tray is rotomolded.