Post-Mounted Tray Assembly

Abstract

A post-mounted tray assembly for mounting to a post, pole, or other vertical support structure includes a first portion defining a first plate and a first mounting bracket, and a second portion defining a second plate and a second mounting bracket. A clamping mechanism including one or more mechanical fasteners may be used for joining the first mounting bracket and the second mounting bracket around the post, such that the post passes through a central aperture defined between the first portion and the second portion.

Description

PRIORITY INFORMATION

The present application claims priority to U.S. Provisional Patent Application Ser. No. 62/733,358, titled “Post-Mounted Tray Assembly,” filed on Sep. 19, 2018, the disclosure of which is incorporated by reference herein.

FIELD OF THE INVENTION

The present subject matter relates generally to tray assemblies, and more particularly to portable, removably mountable tray assemblies with quick installation features.

BACKGROUND OF THE INVENTION

The utilization of “pop-up” style tents has grown tremendously, with primary uses being trade show displays, street vendor events, sports tailgating, and general outdoor recreation. These tents are sold through a variety of outlets, and typically, direct to the end user. Similar larger scale tents are also used at outdoor event functions, such as weddings, corporate events, social gatherings, etc. Most of these units are supplied by rental companies.

Both the “pop-up” style tents and larger assembled onsite event tents typically cater to pedestrian traffic and mingling crowds as opposed to fixed seating. Both tent configurations may be utilized as a shelter for vendors to present and sell merchandise or for purely social gatherings of various sizes. At such events or social gatherings, event hosts prefer to utilize ground and table space for food and beverage serving, special displays, dance floors, etc. As a result, the mobile guests are left to hold their drinks, plates, and personal effects with limited places to set them down.

Tray and shelf solutions have been proposed for mounted trays on tent supports to address the challenges vendors experience related to space restrictions of ground-supported tables and large displays, disruptions to desired traffic flow, and ease of accessibility to critical merchandise or sales material. However, these solutions have several drawbacks. For example, the installation of certain conventional pole-mounted trays requires at least partial disassembly of the support or requires the tray to slide onto the support from one end. In addition, conventional pole-mounted trays require tools or a complex assembly process and may only be mounted on poles having a specific size, cross-sectional shape, and orientation. Furthermore, common tray systems are designed to rest perpendicular to the support pole such that the tray will not be level if mounted on a slanted post.

Accordingly, an improved tray assembly would be desirable. More specifically, a portable, post-mounted tray assembly including features for simplified assembly and versatility of installation configurations would be particularly beneficial.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In a first example embodiment, a post-mounted tray assembly for mounting to a post, pole, or other vertical support structure includes a first portion defining a first plate and a first mounting bracket, and a second portion defining a second plate and a second mounting bracket. A clamping mechanism including one or more mechanical fasteners may be used for joining the first mounting bracket and the second mounting bracket around the post such that the post passes through a central aperture defined between the first portion and the second portion.

These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a top, perspective view of a rectangular tray assembly mounted on a square post according to an exemplary embodiment of the present subject matter.

FIG. 2 provides a bottom, perspective view of the exemplary rectangular tray assembly of FIG. 1 mounted on a square post according to an exemplary embodiment of the present subject matter.

FIG. 3 provides a bottom view of the exemplary rectangular tray assembly of FIG. 1 mounted on a square post according to an exemplary embodiment of the present subject matter.

FIG. 4 provides a close-up, perspective view of a clamping mechanism of the exemplary rectangular tray assembly of FIG. 1 according to an exemplary embodiment of the present subject matter.

FIG. 5 provides a side view of the exemplary clamping mechanism of FIG. 4 according to an exemplary embodiment of the present subject matter.

FIG. 6 provides a side view of the exemplary tray assembly of FIG. 1 mounted on a slanted post according to an exemplary embodiment of the present subject matter.

FIG. 7 provides a side view of the exemplary tray assembly of FIG. 1 mounted on a vertical post according to an exemplary embodiment of the present subject matter.

FIG. 8 provides a top, perspective view of a circular tray assembly mounted on a circular post according to an exemplary embodiment of the present subject matter.

FIG. 9 provides a bottom, perspective view of the exemplary circular tray assembly of FIG. 8 mounted on a circular post according to an exemplary embodiment of the present subject matter.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

Aspects of the present subject matter are generally directed to a tray assembly 100 which may be removably mounted to any post 102, pole, or other suitable vertical or substantially vertical support structure having any suitable cross-sectional shape or size. Specifically, the tray assembly 100 may be positioned around one or more posts 102 at any desired level and in any suitable orientation. In addition, the tray assembly 100 includes a very small number of parts and may be assembled quickly and easily by a single person. Although an exemplary tray assembly 100 is described below for the purpose of explaining the details of the present subject matter, it will be appreciated that the present subject matter may be used in or with any other suitable tray or support surface mounted to a vertical or substantially vertical support structure. Thus, the tray assembly 100 is used in the discussion below only for the purpose of explanation, and as such, use is not intended to limit the scope of the present disclosure to any particular style, configuration, mounting structure, or clamping device of the tray assembly 100.

In general, the tray assembly 100 may include a first portion 110 and a second portion 120 which are joined together to form a single tray with a single horizontal support surface. The first portion 110 and the second portion 120 may be joined to form a rectangular tray, a round tray, an elliptical or oval tray, or a tray having any other suitable shape. In addition, the tray assembly 100 can be manufactured in any suitable size, such as approximately 12″×16″ rectangular shape, 12″ or 16″ circular, or 12″ or 16″ octagonal shape (when assembled). Although exemplary shapes and sizes are described herein, it should be appreciated that tray assembly 100 may be manufactured having any suitable shape and size. It should be appreciated that as used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within a twenty percent margin of error.

The tray assembly 100, regardless of the shape or size, may be composed of two identical molded halves. Thus, according to an exemplary embodiment, the first portion 110 and the second portion 120 are identically sized to form two halves of the tray. Specifically, first portion 110 may define a first plate 112 and second portion 120 may define a second plate 122 that are joined together as described below to form a horizontal support surface. Indeed, as described below, the first portion 110 and the second portion 120 may be identical and may be formed using a single mold. However, according to alternative embodiments, the first portion 110 and the second portion 120 may have different sizes or constructions.

The upper surface of the tray assembly 100 may define a textured top surface for increased friction and reduced sliding of items placed on the upper surface. Regardless of the tray size and geometry, the tray may be designed with a raised containment lip 170 extending around a perimeter 172 of the tray assembly 100, e.g., for retaining items or containing spills. According to alternative embodiments, the tray assembly 100 further defines one or more recessed molded pockets, cup holders, etc.

Below the raised containment lip 170, the tray assembly 100 may define a receiving surface 186 that extends around the perimeter 172 of the tray assembly 100. According to exemplary embodiments, this receiving surface 186 may be configured for receiving a tailored fabric skirt which may be attached to the perimeter 172 of the circular tray via Velcro for more formal settings such as weddings. In this regard, a Velcro fastener strip may be attached to the receiving surface using a suitable adhesive or mechanical fasteners, and the fabric skirt may include a complementary Velcro strip facilitating removable attachment of the skirt.

According to still other embodiments, the tray assembly 100 may include one or more receiving clips, hooks, or other features configured for receiving the fabric skirt. Alternatively, such receiving clips or hooks may be configured for receiving other hanging items or other detachable fasteners to create the look of pub-style tables with table cloths. For example, the receiving surface may define a circumferential groove 194 for receiving an elastic band to secure the fabric skirt, a mounting flange or lip for receiving a complementary band defined on the fabric skirt, etc.

In addition, the tray assembly 100 may include an underside stiffener ribbing structure 190. In this regard, a plurality of elongated ribs 190 may be defined on a lower surface of the tray assembly 100. The ribs 190 may form a lattice structure, a circular structure, a honeycomb structure, or any other suitable structure providing rigidity to tray assembly 100. In addition, the elongated ribs 190 may have any suitable size and thickness for preventing out of plane deformations, bending, or buckling of the tray assembly 100. In addition, as described below, the integrated stiffener ribs 190 may also be used as a rigid structure within which mechanical fasteners of a clamping mechanism 128 may be installed to secure and assemble the tray assembly 100.

The tray assembly 100 may be injection-molded using any suitable plastic or other suitably rigid material. For example, the tray assembly 100 may be molded from plastic-based resins suitable for outdoor use and resistant to harmful effects of moisture, heat, and ultraviolent radiation. In addition, the tray assembly 100 may be molded using material having any desirable color or may thereafter be treated or painted a suitable color.

Specifically, for example, the tray assembly 100 may be formed by injection molding, e.g., using a suitable plastic material, such as injection molding grade high-impact polystyrene (HIPS) or acrylonitrile butadiene styrene (ABS). Alternatively, according to the exemplary embodiment, the tray assembly 100 may be compression molded, e.g., using sheet molding compound (SMC) thermoset plastic.

Although exemplary materials and methods of forming the tray assembly 100 are described herein, it should be appreciated that other manufacturing methods may be used to form the tray assembly 100 using other materials or compositions according to alternative embodiments. The present subject matter is not limited to tray assemblies formed by injection molding or to the materials described herein.

In addition, these features may all be molded as a single, integral piece. Specifically, according to exemplary embodiments, the upper surface of the tray 100, the containment lip 170, the stiffener ribbing 190, integrated stiffeners, and the post clamping device 128 may be integrally formed as a single piece for the first portion 110 and as a single piece for the second portion 120. Notably, including the two mechanical fasteners 130 for joining the first portion 110 and the second portion 120, tray assembly 100 may include a total of four components.

Referring now to FIG. 5, the tray assembly 100 may further define features at the mating edge 192 of the first portion 110 and the second portion 120. For example, the mating edges 192 on each portion may be designed with an overlapping chamfer, a beveled joint, a lap joint, etc. Notably, such features accommodate for slight post 102 variations, degree of tightening, gripping pad compression, and thickness, etc. In addition, such features permit versatile use of the tray assembly 100 while ensuring there is no gap between the first portion 110 and the second portion 120 when installed.

Tray assembly 100 includes features permitting the tray to be mounted on a variety of poles, posts, or other vertical or substantially vertical support structures (referred to herein generally by reference numeral 102) having any suitable size and cross-sectional profile. For example, the two-piece tray and post 102 clamping system 128 is designed to fit both square and round support posts 102 and can accommodate variations in post 102 sizes without affecting the fit-up and stability of the tray assembly 100.

In this regard, the tray assembly 100 may mount on conventional posts 102 common to “pop-up” style event tents, such as 1″ nominal square tubular posts 102. Notably, pop-up style tent square tube posts 102 primarily range from 15/16″ to 1⅛″. In addition, the tray assembly 100 may mount on conventional posts 102 common to larger portable event tents, such as 2″ nominal pipe posts 102 having a substantially circular cross section (see, e.g., FIG. 2). However, it should be appreciated that the tray assembly 100 may also mount to larger or smaller posts 102 according to alternative embodiments.

By using a two piece or split-clamp assembly 128, tray assembly 100 may be mounted around very large pipes. For example, according to exemplary embodiments, extra-long fastening bolts may be substituted for the standard bolts (i.e., mechanical fasteners 130) to fasten the tray around larger posts 102. In this manner, the tray assembly 100 may be mounted on virtually any post 102, regardless of size, if suitably long fastening bolts are used. Notably, the lap joint mating edges 192 may permit installation on such large posts 102 with minimal visual gap between the first portion 110 and the second portion 120.

Furthermore, the mounting assembly and hardware used simplifies the assembly process of the tray assembly 100. In this regard, for example, this system utilizes ergonomic fasteners 130 that may be hand tightened. Specifically, the two-piece tray 100 and post clamping system 128 is designed with a mechanical compression clamp that requires no tools to mount as the two compression bolts 130 have knurled knobs that may be hand tightened. The compression bolts 130 mate into a female insert pressed into the mounting bracket of the opposite tray half, or otherwise machined or mounted onto the mounting bracket. Specifically, a first threaded insert 150 is defined in a first mounting bracket 114, and a second threaded insert 152 is defined in a second mounting bracket 124.

According to the illustrated exemplary embodiment, the tray clamping mechanism 128 generates the mounting compression force using a pair of nominal ¼″ (or 5-6 mm) threaded thumbscrews with knurled knob heads with the shafts passing through a hole in the clamping frame on one tray half (e.g., the first portion 110) and mated to a female threaded insert 152 integrated in the opposing tray half (e.g., the second portion 120). Specifically, according to an exemplary embodiment, each mounting bracket 114, 124 may include a 5/16″ diameter hole for one screw and ¼″ threaded insert 150, 152 for the other (see, e.g., FIGS. 4 and 5). Alternatively, M5 bolts (approximately 0.197″ diameter) and inserts of 0.25″ may be used. Notably, the clamping screws, bolts, or fasteners 130 extend along opposing directions, which may simplify and speed installation since the screws can be tightened concurrently with two hands.

Furthermore, according to an exemplary embodiment, the two clamping screws 130 are inserted in opposing directions so as to create identical mounting frame configurations. In other words, the first portion 110 and the second portion 120 may have identical construction, such that a single mold may be used for fabrication. The thumbscrews and inserts may be made from aluminum, metal alloys, plastics, or other suitable materials. However, it should be appreciated that any other suitable materials may be used for the mounting hardware.

When mounted to a square tube post 102 common to portable “pop-up” style tents, the post 102 may pass through a pre-sized rectangular opening, referred to herein generally as an aperture 140, defined within tray assembly 100 when the first portion 110 and the second portion 120 are joined (see, e.g., FIG. 1). When mounting to such a square tube post 102, the integrated clamping mechanism 128 is designed to urge contact faces (e.g., clamping surface 180 of first portion 110 and clamping surface 182 of second portion 120) toward two opposing flat faces of the square tube post 102. Thus, the clamping frame halves are designed to clamp against two opposing flat faces of the tent post 102. According to exemplary embodiments, the tray assembly 100 may thus be mounted in two orientations relative to the square tube post 102, e.g., orientations separated by 90 degrees as shown for example in FIGS. 1 and 7.

The aperture 140 or tray center rectangular opening may oversized relative to the tent post 102 to permit variations in support post 102 sizes and to accommodate tent posts 102 that are angled, and as such, are not perpendicular to the tray assembly 100 when the tray assembly 100 is adjusted to a level position. According to an exemplary embodiment, the tray assembly 100 is designed to accommodate an angled post 102 up to 15 degrees off of vertical (see, e.g., FIG. 6). The tray assembly 100 can also be mounted at preset locations on the posts 102 or at any other suitable height and/or orientation.

Furthermore, when the tray assembly 100 is mounted to a square tubular tent post 102, it may be mounted such that the tray assembly 100 and posts 102 are not required to be perpendicular (see, e.g., FIG. 6). This feature may be desirable so that the tray assembly 100 can be mounted in a level position while being supported on an angled post 102 up to 15 degrees from vertical, as described above. This is desirable as many portable “pop-up” tents are designed with angled legs, and any tent may be erected on non-level ground which could create a non-vertical post 102.

As shown in FIGS. 8 and 9, according to alternative exemplary embodiments, the tray assembly 100 may have a circular tray configuration. Notably, such a configuration may fit either square tubular posts 102 or the circular pipe posts 102 common to larger event tents. When mounting to circular posts 102, the tray clamping faces 180, 182 may be modified to a hexagonal configuration that creates six gripping points against the circular post 102. According to alternative embodiments, the tray clamping faces 180, 182 may define any other suitable profile (such as any polygonal profile) for engaging any other suitable post 102 size and cross-sectional profile.

Although exemplary embodiments are described herein as including two portions 110, 120 or halves of the tray assembly 100 which are mechanically coupled using fasteners 130 to generate a compression force on a support post 102, it should be appreciated that according to alternative embodiments, a single cantilevered tray assembly 100 may be used. For example, the tray assembly 100 can be modified to use only one half of the tray and the clamping mechanism 128 may include a separate clamping bar so as to mount on one side only of the supporting post 102 should the user desire to arrange tents side by side which prohibits mounting in the standard configuration.

In addition, the tray assembly 100 described herein may mount around more than one support post 102. In this regard, for example, a user could position two tents side by side and the tray assembly 100 may be mounted around two support posts 102 positioned adjacent to and/or in contact with each other. Thus, when a user installs the tray assembly 100, e.g., by positioning both posts 102 through the aperture 140 of the tray assembly 100 and tightening the clamping mechanism 128, the two tents may be joined together as a single structure.

The tray assembly 100 may further include one or more integrated non-slip gripping pads 184 to create both stability and load-carrying capacity. These gripping pads 184 may be attached to the tray assembly 100 after molding, may be over-molded onto the tray assembly 100, may be attached to the post 102 prior to mounting the tray assembly 100, or may be positioned between the tray assembly 100 and the post 102 in any other suitable manner. According to an exemplary embodiment, the gripping pad 184 comprises a 0.125″ nominal non-slip compressible gripping pads 184 at both post 102 contact faces. Such gripping pads 184 may be formed from rubber or another suitable resilient material and may be attached via adhesive to the tray clamping faces 180, 182 to create additional stability and load carrying capacity (see, e.g., FIG. 3). Furthermore, the gripping pads 184 may be compressible and resilient to varying degrees to ensure firm contact is achieved and even pressure is applied to post 102 to secure the tray assembly 100. It should be appreciated that according to alternative embodiments, the gripping pads 184 may have any suitable size, thickness, compressibility, and resiliency. In addition, the gripping pad 184 may be optimized to accommodate variations in post 102 sizes and post 102 materials.

In general, the tray assembly 100 may be used for any suitable purpose. For example, the tray assembly 100 may be used as a “pub table” style solution providing numerous uses, such as holding food or drink at social gatherings, merchandise at consumer displays, giveaways, business cards, etc.

Notably, the tray assembly 100 described above provides a variety of practical advantages over conventional pole-mounted trays. For example, the two-piece tray and post 102 clamping system 128 is designed to be mounted on an erected tent post 102 or other support structure, thus requiring no disassembly of the tent's support frame or posts 102. In addition, the tray assembly 100 is fully attachable/detachable, requires no modifications or permanent attachments to the support posts 102, and leaves no damage to the posts 102 when removed. Furthermore, assembly is simplified because no tools are needed and the mirrored tray halves and opposite mounted fastener threads permit simultaneous installation of the fasteners (e.g., by rotating one fastener with each hand).

The tray or shelf system is also designed to rest in a level position whether mounted to a vertical or slanted support post 102. In this regard, certain “pop-up” style tents utilize slanted legs for added stability. Alternatively, tents using vertical support legs might be mounted on an incline, such that the posts 102 do not extend along the vertical direction. Notably, mounting a tray perpendicular to such non-vertical legs would result in a slanted or non-level support surface. Thus, aspects of the present subject matter and clamping mechanism 128 permit the attachment of tray assembly 100 to non-vertical legs while still providing a support surface that is level or extends in a horizontal plane.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A tray assembly for mounting to a post, the tray assembly comprising:

a first portion defining a first plate and a first mounting bracket;

a second portion defining a second plate and a second mounting bracket; and

one or more mechanical fasteners for joining the first mounting bracket and the second mounting bracket around the post, wherein the post passes through a central aperture defined between the first portion and the second portion.

2. The tray assembly of claim 1, wherein the first mounting bracket is positioned below the first plate and the second mounting bracket is positioned below the second plate.

3. The tray assembly of claim 1, wherein the first mounting bracket is integrally formed with the first plate and the second mounting bracket is integrally formed with the second plate.

4. The tray assembly of claim 1, wherein the first mounting bracket comprises a first threaded insert and the second mounting bracket comprises a second threaded insert.

5. The tray assembly of claim 4, wherein the first threaded insert and the second threaded insert are formed during a molding process or by a machining process.

6. The tray assembly of claim 1, wherein the second portion comprises:

a clamping bar for joining with the first portion.

7. The tray assembly of claim 1, wherein the first portion and the second portion are identical.

8. The tray assembly of claim 1, wherein the tray assembly defines a raised containment lip extending around a perimeter of the tray assembly.

9. The tray assembly of claim 1, wherein the central aperture is square, circular, or polygonal.

10. The tray assembly of claim 1, wherein the first portion defines a first clamping surface and the second portion defines a second clamping surface, the tray assembly further comprising:

a gripping pad mounted to the first clamping surface and the second clamping surface.

11. The tray assembly of claim 10, wherein the gripping pad is compressible to support the tray assembly in a horizontal orientation on a non-vertical post.

12. The tray assembly of claim 1, wherein the tray assembly defines a receiving surface for removably receiving a fabric skirt.

13. The tray assembly of claim 12, wherein the fabric skirt is attached to the receiving surface using Velcro, mechanical clips, or a groove and elastic band.

14. The tray assembly of claim 1, further comprising:

stiffener ribs defined on a lower surface of the first plate and the second plate.

15. The tray assembly of claim 14, wherein a clamping mechanism is defined at least in part by the stiffener ribs.

16. The tray assembly of claim 1, wherein a mating edge is defined by the first plate and the second plate, the mating edge comprising a beveled joint, a chamfered joint, or a lap joint.

17. The tray assembly of claim 15, wherein the clamping mechanism comprises:

two mechanical fasteners the are inserted along opposite directions through the first mounting bracket and the second mounting bracket.

18. The tray assembly of claim 1, wherein two support posts pass through the central aperture.