COMPACT STACKABLE TRAY

Abstract

A compact stackable tray system is disclosed wherein in a first orientation the supports of a lower tray maintain an upper tray away from the lower tray such that one of a plurality of standard milk containers stored on the lower tray may be freely removed and in a second orientation wherein the supports of the lower tray nest within the support of the upper tray such that the lower surface of the upper tray rests against the upper surface of the lower tray.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit, under 35 U.S.C. §119(e), of Canadian Application No. 2,853,385, filed on Jun. 2, 2014, and Canadian Application No. 2,856,688, filed on Jul. 10, 2014. All documents above are incorporated herein in their entirety by reference.

FIELD OF THE INVENTION

The present invention relates to a compact stackable tray. In particular, the present application relates to a stackable tray which in a first orientation supports a like tray positioned above the tray and in a second orientation nests with the like tray.

BACKGROUND

Traditionally, milk in bags is delivered to the merchant in crates stacked on pallets or placed on a stainless steel rolling rack (bossy cart) which can for example be pushed into a refrigerator and be merchandisable without further intervention. The racks are heavy and expensive and lead to injuries and the like. A picked pallet configuration where the pallet is delivered to the merchant preloaded and simply placed in racking and or on the ground from which customers can select the product they wish to purchase is typically preferred given its simplicity. However, current one way solutions which rely on the use cardboard boxes or the like require robust materials which are difficult to dispose of.

What is needed therefore, and an object of the present application is an ecofriendly, inexpensive and convenient means to organize, transport and display for sale milk or other beverages held in bags, cartons or jugs as well as other items such as produce and the like.

An object of the present invention, therefore, is to provide a tray and system that in turn minimises the need for secondary packaging, is retail ready, reusable in a closed loop system and which is stackable and nestable thereby minimizing the space required for empty container storage and return.

SUMMARY OF THE INVENTION

In order to address the above and other drawbacks, there is provided a compact stackable tray configured for stacking with other like trays. The tray comprises a flat rectangular support, a plurality of dividers integral to the support and separating an upper surface of the support into a plurality of compartments, each of the compartments sized to receive a bottom of at least one standard milk container therein, a rim about a periphery of the rectangular support, and a first pair of hollow uprights arranged towards a first short edge of the support and a second pair of hollow uprights arranged towards a second short edge of the support opposite the first edge, the uprights extending above the support to a height above that of a standard milk container when supported on the support. In a first orientation of the tray to an upper like tray, the upper like tray is supported by the uprights of the tray and such that a lower surface of a support of the upper tray is maintained at least a height of the standard milk container above an upper surface of the support of the tray and wherein in a second orientation of the upper tray to the tray rotated 180 degrees horizontally to the first orientation, the hollow uprights of the tray nest within the hollow uprights of the upper tray and such that the lower surface of the support of the upper tray is immediately adjacent the upper surface of the support of the tray when empty and further wherein the uprights combined can support a minimum weight of 160 kgs.

Additionally, there is provided a compact stackable tray system comprising a pair of like compact stackable trays arranged as an upper tray and a lower tray, each of the trays comprising a flat rectangular support, a plurality of dividers separating an upper surface of the support into a plurality of compartments, each of the compartments sized to receive at least one standard milk container therein, a rim about a periphery of the rectangular support, and a first pair of hollow uprights arranged along a first short edge of the support and a second pair of hollow uprights arranged on a second short edge of the support opposite the first edge, the uprights extending above the support. In a first orientation of the upper tray to the lower tray, the upper tray is supported by the uprights of the lower tray such that a lower surface of the support of the upper tray is maintained at least a height of the standard milk container above an upper surface of the support of the lower tray and wherein in a second orientation of the upper tray to the lower tray rotated 180 degrees horizontally to the first orientation, the hollow uprights of the lower tray nest within the hollow uprights of the upper tray and such that the lower surface of the support of the upper tray is immediately adjacent the upper surface of the support of the lower tray and further wherein for each tray the uprights combined can support a minimum weight of 160 kgs.

Also there is provided a compact stackable tray system for stacking milk containers of a plurality of different milk container formats. For a given one of the plurality of standard milk container formats, at least one compact stackable tray is provided comprising a flat rectangular support, a plurality of dividers separating an upper surface of the support into a plurality of compartments, each of the compartments sized to receive at least one standard milk container of the given standard milk container format therein, a rim about a periphery of the rectangular support, and a first pair of hollow uprights arranged along a first short edge of the support and a second pair of hollow uprights arranged on a second short edge of the support opposite the first edge, the uprights extending above the support. In a first orientation, an upper tray is supported by uprights of a lower tray such that a lower surface of a support of the upper tray is maintained at least a height of the given standard milk container of the lower tray above an upper surface of the support of the lower tray and wherein in a second orientation of the upper tray to the lower tray rotated 180 degrees horizontally to the first orientation, if the upper tray and the lower tray are each adapted for stacking a like given milk container format, the hollow uprights of the lower tray nest within the hollow uprights of the upper tray and such that the lower surface of the support of the upper tray is immediately adjacent the upper surface of the support of the lower tray, and if the upper tray and the lower tray are each adapted for stacking a different given milk container format, the hollow uprights of the lower tray are unable to nest within the hollow uprights of the upper tray, and further wherein for each tray the uprights combined can support a minimum weight of 160 kgs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides an isometric view of a pair of compact stackable trays in accordance with an illustrative embodiment of the present invention,

FIG. 2A provides a sectional view of a pair of compact stackable trays along lines IIA-IIA in FIG. 1;

FIG. 2B provides a front plan view of a compact stackable tray in accordance with an illustrative embodiment of the present invention;

FIG. 2C provides a detailed side view of an upright of a lower tray nested in an upright of an upper tray and in accordance with an illustrative embodiment of the present invention;

FIG. 2D provides a top plan view of a compact stackable tray in accordance with an illustrative embodiment of the present invention;

FIG. 3 provides a lowered right front view of a pair of compact stackable trays in accordance with an illustrative embodiment of the present invention;

FIG. 4A provides a raised left front view of a plurality of compact stackable trays in a supported stack in accordance with an illustrative embodiment of the present invention;

FIG. 4B provides a raised left front view of a plurality of compact stackable trays in a nested compact stack in accordance with an illustrative embodiment of the present invention;

FIGS. 4C and 4D provided raised right front views of compact stackable trays in a nested compact stack in accordance with an alternative illustrative embodiment of the present invention;

FIG. 4E provides a raised right front view of a compact stackable tray in accordance with an additional alternative illustrative embodiment of the present invention;

FIG. 4F provides a raised right front view of a stack of compact stackable trays each configured for stacking a different standard milk container format in accordance with an illustrative embodiment of the present invention; and

FIG. 5 is a raised left front view of a compact stackable tray in accordance with an alternative embodiment of the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring now to FIG. 1, a pair of compact stackable trays in accordance with an illustrative embodiment of the present invention will now be described. Each tray, generally referred to using the reference numeral 10, is illustratively manufactured from injection molded plastic and comprises a substantially flat molded plastic tray support 12 divided into a plurality of bag receiving compartments as in 14 by a series of dividers as in 16 aligned with a long edge of the tray 10. Each of the compartments as in 14 may be divided into a pair of subcompartments 18 by provision of an additional divider 20 arranged across a respective compartment as in 14. A first pair of uprights as in 22 is arranged along a first short edge 24 of the tray 10 and a second pair uprights supports as in 26 is arranged along a second short edge 28 of the tray 10. As will be discussed in more detailed below an outer edge 30 of each of the first pair of uprights as in 22 is positioned substantially flush with a respective long edge 32, 34 of the tray 10 while the second pair of uprights as in 26 are positioned away from their respective long edges 32, 34. The dividers as in 16, 20 also provide structural strength to the tray support 12. This allows heavier goods (not shown) to be supported by the support 12 and/or the support 12 to be manufactured from a thinner plastic without the support 12 bending under the weight of those goods.

Still referring to FIG. 1, in the illustrative embodiment each sub compartment as in 18 is sized to accept a conventional milk bag (not shown). As known in the art, such bags each comprise four (4) liters of milk or liquid beverage organized in three (3) smaller bags of 1.33 liters each. Such bags have minimal structural strength and will typically fall over if not supported. The dividers as in 16 are of between 5 and 8 centimeters height to provide some support to the bags and help to maintain them in position and therefore keeping a side of the bag clearly visible, while at the same time being low enough to allow the milk bags to be individually extracted from the tray 10 without undue effort. A rounded upper edge 36 is also provided to the dividers as in 16 to prevent snagging or tearing of the bags during extraction. Each tray 10 also comprises a raised outer rim 38 of about 8 to 12 centimeters, also comprising a rounded upper edge, which provides additional support for bags when the tray 10 is full thereby preventing bags retained within the tray from inadvertently being ejected during transport, for example. In a particular embodiment small drainage holes (no shown) may be provided in each sub compartment as in 18 to allow for water or other liquids to escape, thereby facilitating washing, for example.

Still referring to FIG. 1, each upright as in 22, 26 extends approximately 28 centimeters (11 inches) above the bottom of the tray 10 in order, as will be discussed in more detail below, to provide adequate clearance between stacked trays such that a standard milk bag in between may be freely removed.

Referring to FIGS. 2A and 2B, each of the uprights as in 22, 26 are hollow and illustratively of a rectangular frustum shape and are of the same height (i.e. they extend the same distance above the tray). The outer surfaces as in 40 and the inner surfaces as in 42 of the uprights as in 22, 26 are tapered such that, as will be discussed in more detail below, trays as in 10 may be compactly stacked together by inserting respectively the first uprights 22 and second uprights 26 of a lower tray inside the hollow first uprights 22 and hollow second uprights 26 of an upper tray. In this regard, small holes (not shown) may be provided in the apex 48 of each upright as in 22, 26 to allow air to escape and enter the hollow support during compact nested stacking. Additionally, and with reference to FIG. 2C, the taper of the outer surface 40 and the inner surface 42 of the uprights as in 22, 26 is selected such that during compact stacking, the outer surface 40′ of the uprights as in 22, 26 of a lower tray remain a small distance “d” apart from the inner surfaces 42′ of the uprights as in 22, 26 of the upper tray, or in other words the uprights as in 22, 26 do not bottom out in a compact stacked configuration. This limits sticking, for example when the trays as in 10 are wet or the like allowing for easy unstacking of a compact stack of trays.

Referring to FIG. 2D, each of the trays is rectangular in shape and illustratively 24 inches×20 inches such that four (4) trays as in 10 may be placed in a 2×2 configuration to match the 40 inch by 48 inch foot print of a standard commercial pallet (not shown) and such that when positioned in a rack or the like one of the long edges 32, 34 of each tray, and therefore the individual milk bags, is displayed towards the front of the pallet, thereby allowing the product to be quickly recognized. Additionally, the uprights as in 22, 26 are dimensioned such that five (5) loaded and inverted trays may be stacked together. As each tray carries a maximum of 10 bags, or 40 liters, of milk, the uprights as in 22, 26 uprights together are able to support a weight of at least about 160 kilograms.

Referring to FIG. 3 in addition to FIG. 2A, as will now be appreciated by a person of ordinary skill in the art, trays may be stacked as shown by reversing alternate trays and such that the uprights 22, 26 of the lower tray 10′ engage the underside 44 of the upper tray as in 10. In this regard, the underside 44 of each tray comprises pairs of locating points as in 46 which receive the apex 48 of a respective upright as in 22, 26 therein. Each of the first pair of uprights as in 22 butts against a respective outer tab as in 50 molded in the underside 44 and towards a lower outer edge 52 of the tray being supported, and thereby prevents the tray being supported from sliding on the first pair of uprights as in 22. Similarly, each of the second pair of uprights as in 26 butts snugly against a respective inner tab as in 54 molded in the underside 44 of the tray which thereby prevents the tray being supported from sliding on the second pair of uprights as in 26.

Referring back to FIG. 2A in addition to FIG. 3, the tabs 50, 54 may be tapered such that they better engage the tapered outer surface 40 of their respective uprights as in 22, 26. In this manner the trays are stabilized versus one another thereby limiting shifting during transport or the like. Of note is that, as contact with the underside 44 of the tray 10 is lost below the hollow uprights as in 22, provision of the tabs 54 on the inside of the respective supports as in 26 allows the uprights as in 26 to be positioned somewhat farther apart while still maintaining contact between the apex as in 48 with the underside 44, thereby improving stability. In an alternative embodiment the second pair of uprights as in 26 could be combined into one, with provision of a notch towards the center of the apex of the unified support and a corresponding notch engaging tab in the underside 44 of the tray 10 (all not shown). With brief reference to FIG. 1, additional gussets as in 56 can be added to the uprights as in 22, 26 to improve strength.

Still referring to FIG. 3, a series of indentations as in 58 are typically formed on the underside 44 of the tray 10 opposite the dividers (references 16, 20 in FIG. 1) during manufacture as the plastic cools and contracts. Alternatively, additional ribbing may be added on the underside 44 to increased strength.

Referring now to FIG. 4A, in a first mode of operation trays as in 10 loaded with milk bags as in 60 are stacked in a 2×2 configuration and five high on a standard commercial pallet 62 to form a supported stack 64. As discussed above, in this manner a long edge of each of the trays as in 10, and therefore those of the milk bags as in 60 is visible from the outside and easily recognizable. As the trays as in 10 are emptied, they are simply removed from the top of the stack and placed to the side, typically by the customer given their light weight. In this regard, the empty trays are light enough (for example a maximum of about 3.5 kilograms or 7-8 pounds) such that they can be easily manipulated without the use of gloves or special tools.

Referring now to FIG. 4B, in a second mode of operation, empty trays as in 10 can be stacked as a nested stack 64 by reversing the orientation of the trays, by aligning respectively the first pairs of uprights as in 22 and the second pairs of uprights as in 26 and inserting the uprights 22, 26 of a lower tray into those of an upper tray an such that the lower surface of the upper tray rests upon the upper surface of the lower tray. In this manner, a large number of empty trays can be compactly stacked to facilitate their return to the milk supplier or the like along with the standard commercial pallet 62.

Referring back to FIG. 1, in an embodiment of the tray, for example for use in transporting and displaying other food stuffs such as fresh produce or the like, the dividers as in 16 and 20 may be modified, for example to accommodate cartons or the like, or removed. In this regard, the selection of the thickness of the plastic for use in manufacture of the support 12 will typically be determined by a combination of the presence or absence of the supporting dividers 16, 20 and the weight of the goods to be supported by the tray.

Referring now to FIG. 4C, in a first such alternative embodiment the trays as in 10 are adapted to receive a plurality of standard milk jugs 66. Applicant notes that in conventional systems for the transport of such jugs, subsequent layers of jugs are supported in large part by the jugs underneath. One advantage of such a configuration as disclosed in FIG. 4C, where the jugs as in 66 do not support the upper layer, is that the materials used to manufacture the jugs can be considerably thinner (up to 30%), thereby reducing the costs of the jugs as well as reducing, as the jugs are typically discarded after a single use, the amount of material which is discarded. Additionally, jugs from the lower layers can be withdrawn without risk that the upper layer becomes unstable, or the like.

Similarly, with reference to FIGS. 4D and 4E, in a second and third such alternative embodiment the trays as in 10 are adapted to receive respectively a plurality of one (1) liter milk cartons as in 68 and a plurality of two (2) liter milk cartons as in 70. Again, as the upper layers of cartons 68, 70 do not rest on the lower layers, materials used to manufacture the cartons can be thinner and less robust than a system where the cartons provide some of the support for the upper layers, allowing for relatively inexpensive materials to be used.

With reference to FIG. 4F, an additional advantage of the above is that different products with different formats (bags, jugs and cartons) can be easily mixed on a pallet 62, for example by providing several trays as in 10 of each type of format on each pallet 62. Although in a first embodiment it is foreseen that adapted for use with a different container format are able to nest with one another such that they can be easily stacked, in order to aid in sorting the trays following use and to ensure their return to locations where their respective format is used, in a second embodiment it is foreseen that the uprights of trays adapted for use with different container formats vary such that the tray adapted for use with a first container format is unable to nest with trays adapted for use with a different container format. This can be done, for example by positioning the uprights such that they are slightly closer or farther apart, or by providing a keying system (for example different shaped uprights or the like) such that the uprights of one tray are unable to nest within those of another tray unless they are of the same type. Color coding or the like could also be provided to aid nested stacking of like trays.

Referring now to FIG. 5, in a fourth alternative embodiment of the tray 10 an additional pair of tapered hollow central supports as in 72 is provided and the tray sized to accommodate twenty (20) standard milk bags and for a 2×1 arrangement on a standard commercial pallet. Alternatively, and with appropriate modification, the tray can be adapted to accommodate either jugs or cartons. A first of the pair of central supports as in 72 is positioned flush against the edge of the tray 10 while a second of the of the pair of central supports as in 72 is offset from the tray such that when in a stacked configuration in a first orientation the pair of central supports 72 of the lower tray are engaged by the underside 44 of the upper tray (as are those of the first pair of uprights 22 and the second pair of uprights 26). In a second nested orientation, wherein the upper tray is rotated 180 degrees horizontally to the lower tray, the pair of central uprights 72 of the lower tray are inserted into the pair of hollow central uprights 72 of the upper tray (again, as are those of the first pair of uprights 22 and the second pair of uprights 26). In this orientation the upper surface of the lower tray is directly adjacent the underside 44 of the upper tray.

Although the present invention has been described hereinabove by way of specific embodiments thereof, it can be modified, without departing from the spirit and nature of the subject invention as defined in the appended claims.

Claims

1. A compact stackable tray configured for stacking with other like trays comprising:

a flat rectangular support;

a plurality of dividers integral to said support and separating an upper surface of said support into a plurality of compartments, each of said compartments sized to receive a bottom of at least one standard milk container therein;

a rim about a periphery of said rectangular support; and

a first pair of hollow uprights arranged towards a first short edge of said support and a second pair of hollow uprights arranged towards a second short edge of said support opposite said first edge, said uprights extending above said support to a height above that of a standard milk container when supported on the support;

wherein in a first orientation of said tray to an upper like tray, the upper like tray is supported by said uprights of said tray and such that a lower surface of a support of the upper tray is maintained at least a height of said standard milk container above an upper surface of said support of said tray and wherein a standard milk container positioned in any of said compartments of said tray can be removed across a given long edge of said tray without moving said upper tray and further wherein in a second orientation of the upper tray to said tray rotated 180 degrees horizontally to said first orientation, said hollow uprights of said tray nest within said hollow uprights of the upper tray and such that the lower surface of the support of the upper tray is immediately adjacent said upper surface of said support of said tray when empty and further wherein said uprights combined can support a minimum weight of 160 kgs.

2. The compact stackable tray of claim 1, wherein an apex of each of said uprights is flat.

3. The compact stackable tray of claim 1, wherein each of said first pair of uprights are positioned at a corner of said support and each of said second pair of uprights are positioned between a corner of said support and a center of said second short edge.

4. The compact stackable tray of claim 1, wherein each of said hollow uprights is of a rectangular frustum shape.

5. The compact stackable tray of claim 1, wherein each of said uprights comprises an air hole in a top thereof.

6. The compact stackable tray of claim 1, wherein said rim has a height above said rectangular support is substantially the same or greater than that of said dividers.

7. The compact stackable tray of claim 1, wherein a long edge of each of said compartments is arranged in parallel to a long edge of said support.

8. The compact stackable tray of claim 1, wherein at said standard milk container is selected from a group comprising a standard four liter milk bag, a standard four liter jug, a standard two liter carton or carton and a standard one liter carton or carton.

9. The compact stackable tray of claim 1, wherein at said standard milk container is selected from a group comprising a standard gallon jug, a standard half gallon jug or carton, and a standard one quart jug or carton.

10. The compact stackable tray of claim 8, wherein said standard milk container is a four liter milk bag and further wherein a height of said dividers is sufficient to maintain said standard four liter milk bag in an upright position.

11. The compact stackable tray of claim 8, wherein said standard milk container is a four liter milk bag and further wherein said support is configured to receive ten of said four liter milk bags.

12. The compact stackable tray of claim 8, wherein said standard milk container is a gallon jug and further wherein said support is configured to receive ten of said gallon jugs.

13. The compact stackable tray of claim 8, wherein said standard milk container is a two liter carton and further wherein said support is configured to receive twenty of said two liter cartons.

14. The compact stackable tray of claim 8, wherein said standard milk container is a one liter carton and further wherein said support is configured to receive forty of said one liter cartons.

15. The compact stackable tray of claim 1, wherein in said nested second orientation an outer surface of each of said uprights of said lower tray and an inner surface of each of a respective one of said uprights of said upper tray do not come into contact.

16. The compact stackable tray of claim 1, wherein four of said trays fit snugly in a 2×2 configuration on a standard 40×48 pallet.

17. A compact stackable tray system comprising:

a pair of like compact stackable trays arranged as an upper tray and a lower tray, each of said trays comprising: a flat rectangular support; a plurality of dividers separating an upper surface of said support into a plurality of compartments, each of said compartments sized to receive at least one standard milk container therein; a rim about a periphery of said rectangular support; and a first pair of hollow uprights arranged along a first short edge of said support and a second pair of hollow uprights arranged on a second short edge of said support opposite said first edge, said uprights extending above said support;

wherein in a first orientation of said upper tray to said lower tray, said upper tray is supported by said uprights of said lower tray such that a lower surface of said support of said upper tray is maintained at least a height of the standard milk container above an upper surface of said support of said lower tray and wherein a standard milk container positioned in any of said compartments of said lower tray can be removed across a given long edge of said lower tray without moving said upper tray and further wherein in a second orientation of said upper tray to said lower tray rotated 180 degrees horizontally to said first orientation, said hollow uprights of said lower tray nest within said hollow uprights of said upper tray and such that said lower surface of said support of said upper tray is immediately adjacent said upper surface of said support of said lower tray and further wherein for each tray said uprights combined can support a minimum weight of 160 kgs.

18. The compact stackable tray system of claim 17, wherein the standard milk container is a standard four liter milk bag, wherein a long edge of each of said compartments is arranged in parallel to a long edge of said support, and further wherein a height of said rim is sufficient to maintain a standard four liter milk bag in an upright position.

19. The compact stackable tray system of claim 17, wherein said rim has a height above said rectangular support greater than that of said dividers.

20. A compact stackable tray system for stacking milk containers of a plurality of different milk container formats:

for a given one of the plurality of standard milk container formats, at least one compact stackable tray comprising: a flat rectangular support; a plurality of dividers separating an upper surface of said support into a plurality of compartments, each of said compartments sized to receive at least one standard milk container of the given standard milk container format therein; a rim about a periphery of said rectangular support; and a first pair of hollow uprights arranged along a first short edge of said support and a second pair of hollow uprights arranged on a second short edge of said support opposite said first edge, said uprights extending above said support;

wherein in a first orientation, an upper tray is supported by uprights of a lower tray such that a lower surface of a support of said upper tray is maintained at least a height of said given standard milk container of said lower tray above an upper surface of said support of said lower tray and wherein a standard milk container positioned in any of said compartments of said lower tray can be removed across a given long edge of said lower tray without moving said upper tray and further wherein in a second orientation of said upper tray to said lower tray rotated 180 degrees horizontally to said first orientation, if said upper tray and said lower tray are each adapted for stacking a like given milk container format, said hollow uprights of said lower tray nest within said hollow uprights of said upper tray and such that said lower surface of said support of said upper tray is immediately adjacent said upper surface of said support of said lower tray, and if said upper tray and said lower tray are each adapted for stacking a different given milk container format, said hollow uprights of said lower tray are unable to nest within said hollow uprights of said upper tray, and further wherein for each tray said uprights combined can support a minimum weight of 160 kgs.

21. The compact stackable tray system of claim 20, wherein the plurality of different milk container formats are selected from a group comprising a standard four liter milk bag, a standard gallon jug, a standard two liter carton and a standard one liter carton.