STACKABLE TRAY
A stackable tray may have a main bottom panel and a plurality of wall members extending from the main bottom panel that are adaptable to be folded about a respective plurality of score lines to form a tray. The main bottom panel may have at least one perforation that is at least partially deformable due to engagement of the main bottom panel with a protrusion of a pre-determined item located beneath the tray in the vicinity of the at least one perforation. A blank for forming a stackable tray and a plurality of stackable trays are also disclosed.
This application relates generally to stackable trays for use in supporting, transporting, storing, and carrying several beverage containers or other items. Businesses such as grocery stores, convenience stores, gas stations, distribution companies, and manufacturing companies that buy, sell, transport, or distribute beverage containers often utilize various stackable trays or cases to allow for the easy movement or storage of multiple beverage containers at once. Stackable beverage trays provide stability to stack beverage containers on top of other beverage containers to maximize space in storage containers or transportation vehicles. Many stackable beverage trays are made of plastic or similar synthetic thermoplastic or thermosetting material making them expensive to make, maintain, and store. Also, stackable beverage trays made of plastic or similar synthetic thermoplastic or thermosetting material are relatively heavy, and may increase transportation costs due to the increased weight of the beverage trays. Additionally, the increased weight may make stacking and unloading the beverage trays more difficult. Some plastic stackable beverage trays are pre-formed or pre-molded, and take up a large amount of volumetric space when stored without beverage containers.
Some stackable beverage trays enable beverage containers in lower stacked beverage trays to nest with or engage recesses in upper stacked beverage trays or upper stacked beverage containers. These recesses enable the upper stacked beverage containers to align or to remain in an aligned position with the lower stacked beverage trays during shipping, storing, or carrying, and provide stability to multiple stacked beverage trays. However, many recesses do not “lock” or firmly secure the upper stacked beverage trays onto the lower stacked beverage containers, potentially causing damage to the lower stacked beverage containers due to movement, vibration, or other stresses that may be caused during transporting, storing, or carrying. For example, some stackable beverage trays contain shallow depressions or recesses such that during a sudden stop when transporting, the upper stacked beverage tray may slide off of the tops of lower stacked beverage containers causing the upper stacked beverage containers in the upper stacked beverage trays to fall down, possibly causing a rupture, breakage, or other similar damage in the upper stacked beverage containers.
Additionally, some beverage trays contain deeper depressions or recesses that more firmly secure upper stacked beverage trays onto lower stacked beverage containers, but may cause other problems in carrying or unloading the beverage trays. For example, when removing or unloading some upper stackable beverage trays from lower stacked beverage trays, a worker may horizontally or laterally slide, instead of lift, the upper stacked beverage tray off the tops of the immediately lower stacked beverage containers, potentially causing the tops or caps of the lower stacked beverage containers to break, shear, open, or potentially cause other similar damage to the immediately lower stacked beverage containers.
Thus, there is a need for a stackable tray that is inexpensive to make, maintain, and store. There is also a need for a lightweight stackable tray to reduce shipping costs and to make it easier to stack and unload, and which is disposable. Additionally, there is also a need for a stackable tray that secures upper stacked trays onto lower stacked trays, enabling a person to unload or remove the upper stackable trays by slightly lifting the upper stackable trays from the immediately lower stacked trays, but not allowing a person easily to horizontally or laterally slide the upper trays from the lower stacked beverage containers or other items in the lower stacked trays.
SUMMARYA stackable tray may have a main bottom panel and a plurality of wall members extending from the main bottom panel that are adaptable to be folded about a respective plurality of score lines to form a first tray. The main bottom panel may have at least one perforation that is at least partially frangible due to engagement of the main bottom panel with a protrusion of a pre-determined item, to be contained within a second tray located beneath the first tray, in the vicinity of the at least one perforation. A blank for forming a stackable tray and a plurality of stackable trays are also disclosed.
As used herein, the following terms should be understood to have the indicated meanings:
When an item is introduced by “a” or “an,” it should be understood to mean one or more of that item.
“Beverage container” means a container suitable for containing a beverage or other potable liquid, such as, but not limited to, a bottle, a can, a jug or other suitable vessel. A beverage container may be any suitable size and may have any suitable shape, including without limitation cylindrical, spherical, elliptical, rectangular, square, pyramidal, irregular, or a combination of any of the foregoing.
“Beverage tray” means a case, tote box, removable receptacle, crate, or other container that may be used, for example, to hold, transport, carry, or store one or more beverage containers.
“Blank” means a sheet of material adaptable for forming a tray or a portion of a tray.
“Comprises” means includes but is not limited to.
“Comprising” means including but not limited to.
“Corrugated” means having a wave-like shape.
“Fastened” means, with respect to two or more items, attached in any manner, including but not limited to attached by one or more rivets, nails, screws, pins, stitches, staples, brads, glue or other adhesives, straps, bracing, strapping, fittings, or a combination thereof.
“Fiberboard” means an assembly of two or more paperboard components. Fiberboard may or may not have one or more corrugated members.
“Flap” means a portion of a tray that may be folded and fastened to another portion of the tray. A flap may be fastened to a panel, another flap, or some other portion of a tray.
“Having” means including but not limited to.
“Liquid container” means a container suitable for containing a liquid, such as, but not limited to, a bottle, a can, a jug or other suitable vessel. A liquid container may be any suitable size and may have any suitable shape, including without limitation cylindrical, spherical, elliptical, rectangular, square, pyramidal, irregular, or a combination of any of the foregoing.
“Member” means a portion of a tray. A member may include but is not limited to a flap or a panel.
“Panel” means a side of a tray, regardless of its orientation or position with respect to other portions of the tray. A panel may form a top, bottom, front, back, lateral, or other side of a tray.
“Paperboard” means a sheet of material comprising cellulose fibers, wood fibers, wood pulp, other plant fibers, recycled paper, other suitable fibrous material, or a combination thereof.
“Perforation” means an area of weakening in a material to facilitate tearing, punching through, or otherwise removing a portion of the material. A perforation may include but is not limited to one or more cuts, holes, slits, scores, slit-scores, indentations, thinned areas, creases, or combinations thereof. A perforation may or may not traverse completely through the material, and the removed portion of material facilitated by a perforation may or may not become separated from the remainder of the material. A perforation may be made by cutting, scoring, slit-scoring, piercing, punching, crimping, creasing, grinding, filing, melting, burning, chemical etching, or any other suitable method.
“Shrink wrap” means a plastic or other flexible material that may be used to wrap or seal one or more items, such that when the plastic or other flexible material is exposed to a heat source, it generally shrinks to the contour of the one or more items.
“Slit-score” means a cut extending through only a portion of the thickness of a member.
“Substantially continuous” means, with respect to a piece of material, not having any significant holes that traverse through the material.
“Tray” means a container having an open side that may be used to contain one or more liquid containers or any other suitable object. A tray may be any suitable size and may have any suitable shape, including without limitation cylindrical, spherical, elliptical, rectangular, square, pyramidal, irregular, or a combination of any of the foregoing.
“Wrapper” means a thin flexible material that may be wrapped about one or more items.
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In some embodiments, stackable beverage trays may be designed to allow the upper beverage tray 23 to easily separate from the lower beverage tray 25 while unloading or lifting the upper beverage tray 23 from the lower beverage tray 25 in order to protect both the stackable beverage trays and the caps or protrusions of beverage containers 15 or other items. Perforations 3 may be made in fiberboard or other material that may easily separate from the main bottom panel 11 of an upper beverage tray 23 if, for example, the perforations 3 snag or catch on protrusions from a lower level stacked item. For example, a crimped cap 16 on a lower level beverage container 15 may engage perforations 3 on the upper beverage tray 23 such that the perforations 3 tightly grip the crimped cap 16. In this embodiment, when lifting the upper beverage tray 23 from the lower beverage tray 25, the perforations 3 on the upper beverage tray 23 may partially or fully separate from the main bottom panel 11 of the upper beverage tray 23 while continuing to grip the lower level crimped caps 16. Of course, the separation of the perforations 3 from the main bottom panel 11 of the upper beverage tray 23 may not affect the load capacity or integrity of the upper beverage tray 23. Also, partial or full separation of the perforations 3 from an upper beverage tray 23 may occur during loading, shipping, transporting, or other similar activity if the caps or protrusions of the lower level beverage containers 15 or other items snag or catch perforations 3 on the upper beverage tray 23. A person of ordinary skill in the art will recognize that perforations 3 on an upper beverage tray 23 may be adaptable to prevent damage to other types of caps or protrusions on the tops of beverage containers 15 or other items.
Although various exemplary embodiments have been shown and described, the invention is not limited to the embodiments shown and described. Therefore, the scope of the invention is intended to be limited solely by the scope of the claims that follow, considering the doctrine of equivalents.
Claims
1. A blank for forming a stackable tray comprising:
- a main bottom panel and a plurality of wall members extending from said main bottom panel;
- said plurality of wall members adaptable to be folded about a respective plurality of score lines to form a tray;
- said main bottom panel comprising at least one perforation;
- said at least one perforation adapted for engaging a protrusion of a pre-determined item to be located beneath said tray.
2. The blank of claim 1 wherein said main bottom panel and said plurality of wall members comprise fiberboard.
3. The blank of claim 1 wherein said main bottom panel and said plurality of wall members comprise a water resistant material.
4. The blank of claim 1 wherein said plurality of wall members comprises at least one flap.
5. The blank of claim 1 wherein said plurality of wall members comprises at least one panel.
6. The blank of claim 1 wherein said blank further comprises one or more handles.
7. The blank of claim 1 wherein said pre-determined item comprises a beverage container.
8. The blank of claim 1 wherein said at least one perforation is sized and positioned to substantially align with at least one predetermined item to be placed in said tray.
9. A stackable tray comprising:
- a main bottom panel;
- said main bottom panel comprising at least one perforation;
- said main bottom panel being adaptable as a base for supporting a first pre-determined item;
- a plurality of side members extending from said main bottom panel;
- said stackable tray being stackable on top of a second pre-determined item;
- said at least one perforation being sized and located for engagement of said main bottom panel with a protrusion of said second pre-determined item in the vicinity of said at least one perforation;
- said at least one perforation being configured to at least partially deform due to said engagement when said stackable tray is stacked on top of said second pre-determined item.
10. The stackable tray of claim 9 wherein said stackable tray comprises fiberboard.
11. The stackable tray of claim 9 wherein said stackable tray comprises water resistant material.
12. The stackable tray of claim 9 wherein said plurality of side members comprises at least one of flap.
13. The stackable tray of claim 9 wherein said plurality of side members comprises at least one panel.
14. The stackable tray of claim 9 wherein said stackable tray further comprises one or more handles.
15. The stackable tray of claim 9 wherein said at least one perforation is adapted to allow said protrusion of said second pre-determined item to engage with a recess on said first pre-determined item.
16. The stackable tray of claim 9 wherein a portion of said main bottom panel in the vicinity of said at least one perforation is adapted to engage with a recess on said first pre-determined item.
17. The stackable tray of claim 9 further comprising a wrapper disposed about said stackable tray and said first pre-determined item.
18. The stackable tray of claim 17 wherein said wrapper comprises shrink wrap.
19. The stackable tray of claim 9 wherein said at least one perforation is configured to substantially align with said first pre-determined item.
20. The stackable tray of claim 9 wherein said at least one perforation comprises a plurality of perforations that are respectively sized and positioned to substantially align with respective ones of a first plurality of pre-determined items in said stackable tray and a second plurality of pre-determined items in a lower tray.
21. A plurality of stackable trays comprising:
- an upper tray comprising a first plurality of pre-determined items;
- a lower tray comprising a second plurality of pre-determined items;
- said upper tray being disposed on top of said lower tray;
- said upper tray having a main bottom panel comprising a plurality of perforations;
- said plurality of perforations being at least partially deformed due to engagement of said main bottom panel by respective protrusions of said second plurality of pre-determined items.
22. The plurality of stackable trays of claim 21 wherein said plurality of perforations is substantially aligned with respective ones of said protrusions.
23. The plurality of stackable trays of claim 21 wherein said plurality of perforations is substantially aligned with said first plurality of pre-determined items.
24. The plurality of stackable trays of claim 21 wherein said upper tray is stacked in a staggered manner with respect to said lower tray.
25. The plurality of stackable trays of claim 21 wherein said plurality of perforations is configured to be frangible in a desired amount based on a pre-determined weight associated with said first plurality of pre-determined items.
26. The plurality of stackable trays of claim 21 wherein said first plurality of pre-determined items and said second plurality of pre-determined items are the same.
27. The plurality of stackable trays of claim 26 wherein said first plurality of pre-determined items and said second plurality of pre-determined items comprise beverage containers.
28. The plurality of stackable trays of claim 21 wherein at least one of said plurality of perforations is at least partially broken.
29. A stackable beverage tray comprising:
- a main bottom panel comprising fiberboard;
- said main bottom panel having a plurality of perforations and being substantially continuous in the vicinity of each of said plurality of perforations;
- said main bottom panel being adaptable as a base for supporting a first plurality of beverage containers;
- said stackable beverage tray being stackable on top portions of a second plurality of beverage containers disposed below said stackable beverage tray such that said top portions respectively engage said main bottom panel in the vicinity of respective ones of said plurality of perforations and thereby cause at least some of said plurality of perforations to become at least partially broken.
30. The stackable beverage tray of claim 29 wherein said fiberboard comprises corrugated fiberboard.
31. The stackable beverage tray of claim 29 wherein each of said plurality of perforations is placed in a pre-selected location corresponding to a location of a beverage container disposed within a lower tray when said stackable beverage tray is stacked on said lower tray.
32. The stackable beverage tray of claim 31 wherein said main bottom panel is adaptable for receiving said first plurality of beverage containers in a configuration in which each of said first plurality of beverage containers is substantially aligned with a respective one of said plurality of perforations.
33. The stackable beverage tray of claim 31 wherein said main bottom panel is adaptable for receiving said first plurality of beverage containers in a configuration in which said first plurality of beverage containers is substantially offset from said plurality of perforations.
34. The stackable beverage tray of claim 29 further comprising a plurality of side members extending from said main bottom panel.
35. The stackable beverage tray of claim 34 wherein said plurality of side members is sized such that said first plurality of beverage containers protrudes above said plurality of side members.
36. A stack of beverage trays comprising:
- a first beverage tray comprising a fiberboard bottom panel and a plurality of fiberboard side members extending from said bottom panel;
- said bottom panel having a plurality of perforations and being substantially continuous in the vicinity of each of said plurality of perforations;
- a first plurality of beverage containers disposed in said first beverage tray;
- a second beverage tray having a second plurality of beverage containers therein;
- said first beverage tray being stacked on top portions of said second plurality of beverage containers such that said top portions respectively engage said bottom panel in the vicinity of respective ones of said plurality of perforations such that said plurality of perforations are at least partially broken.
37. The stack of beverage trays of claim 36 wherein said first beverage tray is substantially aligned with said second beverage tray.
38. The stack of beverage trays of claim 36 wherein said first beverage tray is substantially offset from said second beverage tray.
39. The stack of beverage trays of claim 36 wherein said second beverage tray is substantially the same as said first beverage tray.
40. The stack of beverage trays of claim 36 wherein said top portions of said second plurality of beverage containers at least partially protrude into respective recesses of said first plurality of beverage containers.
41. The stack of beverage trays of claim 36 wherein said first plurality of beverage containers is substantially the same as said second plurality of beverage containers.
42. The stack of beverage trays of claim 36 wherein at least one of said first beverage tray and said second beverage tray comprises a wrapper disposed thereabout.
Type: Application
Filed: Nov 5, 2008
Publication Date: May 6, 2010
Inventor: Vito Biundo (Webster Groves, MO)
Application Number: 12/265,614
International Classification: B65D 21/032 (20060101); B65D 71/72 (20060101);