Note: Descriptions are shown in the official language in which they were submitted.
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NESTABLE AND STACKABLE TRAY FOR CANS OR THE LIKE
BACKGROUND OF THE INVENTION
The present invention relates to low depth, nestable trays for transporting
and storing beverage containers, such as twelve-ounce aluminum cans and two-
S liter plastic bottles.
Cans for soft drinks, beer and other beverages are often stored and
transported during the distribution stages thereof in short-walled cardboard trays
or boxes. These cardboard trays are generally not rugged enough for reuse and
therefore must be discarded by the retailer at his expense. They are flimsy and
can collapse when wet. They also are unattractive and do not permit the full
display, merchandising and advertising of the cans. Thus, there has been a need
for a returnable and reusable tray for storing and transporting cans and the like.
This tray should be light weight, easy to manipulate and carry, and
economically constructed, since the non-reusable cardboard trays which it
replaces cost generally less than a dime. An example of a relatively recent,
returnable and reusable tray of the present assigned and particularly adapted for
handling twenty-four twelve ounce, pull-top aluminum cans is that disclosed in
U.S. Patents 4,932,532 and 5,277,316.
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When empty the re~-cable plastic trays of U.S. 4,932,532
are nestable one within the other so as to occupy less storage space
and to be more easily handled. The trays are unfortunately nestable
only to a small extent, perhaps one-quarter of their total height. In
other words, each additional tray adds about three-quarters of the
total tray height to the stack of empty trays. A large amount of stor-
age space is thus needed for the empty trays, and the stack of trays
can be rather tall and cumbersome. The sides of that tray are solid
around their perimeter, and thus the lower portions ol the cans or
other containers held therein, Pspec~ally when the loaded trays are
stacked, are not e~rose~1. This prevents the containers therein from
being readily seen to both determine how full the trays are and also
the container brand from its label.
Rellc~ble plastic cases have also been developed for transport-
ing and storing bottles such as two-liter beverage bottles. An exam-
ple of a recent plastic, nesting and stacking storage container is that
disclosed in U.S. Patent 4,823,955 of the present assignee. These
cases often have a height which is greater than the height of the bot-
tles contained therein such that when stacked the cases do not rest on
top of the bottles in the lower case. Rather, the sides of the cases
bear the loads of the upper cases and their contents. These cases are
expensive to manufacture, to ship and to store empty as they are rel-
atively large and occupy a great deal of space. Since they totally
surround the bottles held therein, they prevent them from being fully
displayed.
Plastic low depth cases have thus been developed wherein the
side walls are lower than the height of the stored bottles. The bottles
contained in a lower case thereby support the weight of the other
cases stacked on top of them. Today's plastic, polyethylene
terephthalate (PET), bottles have become particularly popular because
of their transparency, light weight and low cost. Even though they
are flexible, their walls are strong in tension and thus can safely con-
tain the pressure of carbonated beverages therein. Their flexible
walls can bear surprisingly high compressive loads as well, as long as
these loads are applied axially. Thus, it is important that the bottles
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do not tip in their cases or trays, as the loads thereon when stacked
would then not be along the longitudinal axes of the bottles, and the
loaded bottles can thereby be caused to buckle. This is particularly
true for the larger capacity PET bottles, such as the two-liter ~ottles
widely used for soft drinks today. Thus, some of the prior art cases
require additional structure therein to hold the bottles stable. Others
have han~l1Pe which mu_t be removed in order to stack the empty
cases, which is an inconvenient and time con-c-~ming step. Some of
these low depth cases also have higher walls which reduce their dis-
play c~p~hilities.
One commercially successful design of the
stackable low depth cases particular suitable for the two-liter PET bottles
is the "Castle Crate~ design of the present assignee, such as is disclosed in
U.S. Patent 4,899,874. For this genre of cases a plurality of columns project
upwardly from the bottom case portion and together with the side
walls help define a plurality of bottle retaining pockets. This case
with its internal colum~el when empty, rP-semblff a medieval castle.
These columns are hollow to permit empty crates to stack top to bot-
tom. These low-profile crate designs have spaced side columns to
provide added s~rength and yet still expose the containers therein.
This design though requires a certain registration of the empty crates
for nesting purposes m~king the procedure a slight bit more cumber-
some and time cor~cuming than desirable.
Beverages in the twelve or sixteen ounce sizes are often sold,
as in convenience stores, loose or individually, that is, not in an
attached six-pack arrangement. To remove the bottles or cans from
their six-pack (secondary) packaging, whether a shrink wrap, a card-
board enveloping carton, or an interconnected plastic ring arrange-
ment, is a labor intensive procedure.
Some of the known trays do not hold their beverage containers
in a contin~lolle spaced relation so that the containers rub against one
another or crate structure while in transport. This action can rub off
the container labels or scratch the containers, and is a particular
problem for metal soft drink and beer cans.
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Pull-top al-lminum cans for soft drinks and other beverages are usually
stored and ~l~dnspol~d in short-walled cardboard trays or in cardboard boxes.
On the other hand, be~use of the ever increasing cost in disposable tertiary
S pac1~gin~, returnable, reusable cont~iners are becoming popular for the storage
and handling of bot~es. However, unlike plastic or glass bottles which have
rounded edges on their crown or top, pull-top aluminum cans have square sharp
corners where the top of the can attaches to the side walls. Therefore,
particular difficulties have been encountered in the stacking and manipulating of
the trays of cans stacked relative to one another. In fact, aside from tray of
U.S. 4,932,532 there are no pAor known returnable, reusable trays suitable for
~u~ olLing pull-top ~ minum cans and which can, when filled with such cans,
be stacked securely one on top of another, so that the top tray of a stack of
filled trays can be easily pulled off and along the stack without being lifted. In
other words, the trays should be constructed so that when loaded they can be
easily pivoted and slid off of loaded trays beneath them without having to be
lifted.
SUMMARY OF THE INVENTIQN
Accordingly, it is a princip~l object of an aspect of the present invention
to provide an improved nestable, low depth tray for storing and transporting
containers, such as beverage cans and bottles.
Another object of an aspect of the present invention is to provide an
improved low-depth can tray which, when loaded and stacked on a similar
loaded tray ben~P~th, is securely supported but can be easily slid on and along
the cans beneath it when desired.
A further object of an aspect of the present invention is to provide an
improved low-depth, nestable container tray design which occupies less space
both when in a loaded stacked relation and when in an empty nested relation.
A still further object of an aspect of the present invention is to provide
an improved low-depth, nestable tray design which has an open side
configuration thereby allowing the containers loaded therein to be readily and
more fully seen, counted, idell~ifi~ and displayed.
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Another object of an aspect of the present
invention i8 to provide improved low-depth, nestable
trays which can be readily stacked in a deeply nested
relation when empty without requiring any extra or
special manipulation of one tray relative to another.
A further object of an aspect of the present
invention i8 to provide an improved low-depth, nestable
tray which can hold loose cans therein in a compact
array while preventing them from rubbing against one
another during transport.
A still further object of an aspect of the present
invention i8 to provide a plastic low depth, nestable
tray which i8 light weight, economical to manufacture
and attractive.
Another object of an aspect of the present
invention i8 to provide an improved reusable tray which
can transport and store loose contA;ners as well as
those connected and held securely in a six-pack
arrangement.
Other aspects of this invention are as follows:
A low depth, nestable tray comprising:
a substantially flat, open floor top surface having
a plurality of support areas for supporting contA;ners
thereon, each said support area being configured for
vertically upright supporting a separ2te f luid contA;ner
having a right circular cylindrical vertical side wall,
said floor having a bottom surface with an array of
receiving areas for receiving thereon the tops of
similar fluid contA;ners in at least one similar tray
beneath said floor;
a low-depth tray rail spaced above and generally
parallel to said floor, said rail being positioned
relative to said floor such that the tops of the f luid
containers supported on said support areas
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extend a distance abo~e a top surface of said rail and
thereby in a low-depth arrangement;
wherein said rail has an inboard rail surface,
disposed inboard relative to said floor;
wherein said inboard rail surface has thereon a
plurality of vertically upright, right circular
cylindrical surfaces, each conforming to the shape of
the cylindrical side walls of the fluid contA;ners
supported ~ertically upright on adjacent said support
areas, to thereby provide lateral support along the
lengths of said cylindrical surfaces for the adjacent
fluid contA;ners against their cylindrical side walls;
and
a plurality of nesting columns ext~n~;ng down from
said rail and angling downwardly and inwardly to said
connecting with said floor, said coll~ns being spaced
around an outer perimeter of said floor and defining
open through-spaces between adjacent said columns.
A method of handling loaded trays, said method
comprising the steps of:
providing first and second low-depth stackable
trays, said trays having a substantially flat, open
floor top surface with a plurality of support areas for
supporting containers thereon, both trays having
downwardly raised members on the bottom floor surfaces
thereof, both trays being loaded with respective first
and second layers of cans, each of the cans having
raised top rims;
stAck;ng the loaded first tray on the loaded second
tray such that the raised members on the bottom of the
first tray are in a locked position relative to the rims
of the second layer of cans in the loaded second tray
therebeneath, thereby defining at least in part a loaded
tray stack;
moving the loaded tray stack to a different
location;
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at the different location, twisting, without
significantly lifting and about a generally vertical
axis, the loaded first tray on the rims of the second
layer to position the raised members on the loaded first
tray in an unlocked position with respect to the rims of
the second layer; and
with the loaded first tray in the unlocked
position, sliding the loaded first tray on and along the
rims of the second layer.
A low depth tray for cylindrical contA;ners adapted
to be nested with other trays when empty of the
contA;ners and stacked with other trays when loaded with
the contA;ners, said tray comprising:
a low depth side wall structure comprising a band
ext~n~;ng around the periphery of said tray for
preventing the cylindrical contA;ners from tipping
during transport;
a floor structure connected to said wall structure,
said floor structure comprising
a substantially flat, open floor top surface having
a plurality of support areas for supporting the
contA;nPrs thereon, and
a floor bottom surface having a plurality of spaced
downward projections adapted to prevent free sliding of
said tray when loaded with the containers and stacked
with other trays, the contA;ners each having a top
surface defining top rims of the cont~;ners, wherein
said projections are positioned to be within the top
rims of contA;ners in an adjacent tray beneath said tray
when loaded with contA;nPrs and stacked, and also
positioned to surround the top rims of contA;ners in an
adjacent tray beneath said tray when loaded with
contA;nPrs and stAcke~, thereby providing rotatably
releasable engagement of the bottom of an adjacent tray
with the top rims of contA;ners loaded in said tray
therebeneath; and
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a plurality of columns interconn~cting said band
and said floor structure, said columns configured to
nest deeply with columns of another empty tray.
Directed to achieving these objects, a novel low-
depth, nestable tray for beverage contA;ners is herein
provided. This tray is formed by integrally molding
from plastic three basic c~rQn~nts -- a floor, an upper
rail and a plurality of generally conical columns. The
floor has on its top surface a plurality of fluid
contA;ner support areas, each for supporting thereon a
separate fluid contA;ner. The bottom floor surface in
turn has a nl~her of receiving areas for receiving
thereon the tops of similar fluid contA;ners in a layer
in a similar tray beneath the floor. The rail is formed
by an upright band having vertical inner and outer
surfaces and a lip at the top thereof projecting
outwardly a slight distance. The rail is positioned
generally parallel to and above the floor 80 as to be
below the tops of the fluid contA;ners when resting on
the floor, and thereby in a low-depth arrangement, but
high enough relative to them to prevent them from
tipping. The columns extend between, interconnect and
merge with the floor and the rail. The are spaced
around the outside of the floor and between adjacent
support area~. Each of them has a generally truncated
conical shape and defines a longitll~;nAl slot disposed
out-wardly relative to the floor and ext~n~;ng generally
from the bottom of the floor up to the lip. The slots
taper upwardly, are inclined inwardly towards the floor,
and are configured to slidingly receive therein the
inner surfaces of similar columns in a similar tray
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therebeneath such that the floor fits within the open rail when the
trays are in an empty nested relation. The areas between the adja-
cent columns and between the rail and floor and along both sides and
ends are open, providing a light weight design which allows more
complete vicu~ ation and display of the containers held in the tray.
The floor preferably has an open grid-work design which not only is
attractive and allows unwanted fluids to drain out of the tray, but also
requires less plastic material and therefore is lighter and cheaper
than a solid floor design. Stability corner posts extending downwardly
and inwardly from the rail to the floor corner support areas can also
be provided according to one preferred embodiment.
The tray can be dimensioned and configured for generally any
type and number of beverage containers. As an example, one tray of
this invention carries eight two-liter PET bottles and another carries
twenty-four twelve ounce metal cans. These pull-top type of cans
each have sharp top rims. Since the tray is molded of a plastic having
a low coefficient of friction, a loaded top tray would slide too freely
on the layer of can rims beneath it if the tray bottom were smooth.
On the other hand, a sliding action is desirable when manu~lly unload-
ing a loaded tray off of a tall stack of trays. Accordingly, the bottom
of the tray floor is molded with a pattern of redoubt members or
downward protuberances to help locate an upper tray on a loaded
lower tray beneath it. These protuberances are positioned so to
define recessed areas between them up into which the rims of the
layer of cans beneath it fit. The recessed areas should be wide enough
to accommodate actual h~nrlling conditions, including cross-stacking
patterns, wherein the cans do not line up precisely one on top of the
other. On the other hand, the protuberances should provide enough
surface area so they do not get worn off too quickly, as when a line of
loaded trays are pushed along a concrete floor. Thus, the tray floor
bottom is designed so that the recessed areas each have a sufficient
clearance width and the remainder of the floor bottom comprises
protuberance surfaces. Some of the protuberances are thus positioned
within or inside their corresponding can rim and the rem~inder inter-
stitially between a square of can rims. Some of the interstitial
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protuberances will also engage the perimeter of the floor. Thus, with
the top tray located on a layer of cans beneath it the can rims are
positioned in the recessed areas and the trays are in a locked position.
The protuberances have their perimeter edges bevelled. Thus, with
the trays in the locked position the top tray can be twisted a slight
angle, the protuberances ride up their bevelled edges on the rims to
an unlocked position and the loaded top tray slid freely on and along
the rimmed cans beneath it.
Other objects and advantages of the present invention will
become more apparent to those persons having ordinary skill in the
art to which the present invention pertains from the following
description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a top perspective view of a first tray of the present
invention.
Figure 2 is a top plan view of the first tray.
Figure 3 is a bottom plan view of the first tray.
Figure 4 is a side elevational view of the first tray.
Figure 5 is an end elevational view of the first tray.
Figure 6 is a cross-sectional view taken along line 6-6 of
Figure 2.
Figure ~ is a cross-sectional view taken along line ~-~ of
Figure 2.
Figure 8 is a cross-sectional view taken along line 8-8 of
Figure 4.
Figure 9 is a cross-sectional view taken along line 9-9 of
Figure 5.
Figure 10 is a cross-sectional view taken along line 10-10 of
Figure 2.
Figure 11 is a cross-sectional view taken along line 11-11 of
Figure 2.
Figure 12 is a cross-sectional view taken along line 12-12 of
Figure 2.
Figure 13 is a side elevational view, with portions thereof bro-
ken away, of the first tray in an empty and nested position.
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similar loaded tray 120 therebeneath without having to be lifted off
therefrom thereby m~king it easier to handle the loaded and stacked
trays.
The rail 106 is positioned by the columns 108 above the floor
104 a sufficient height to prevent the containers 102 held on the floor
from tipping when the tray 100 is being transported. It is low enough,
however, in a "low depth" configuration, so that the tops of the con-
tainers 102 on the floor 104 extend above it, and the containers them-
selves then directly support the weight of loaded trays thereabove, as
can be understood from Figure 14. Unlike the earlier-mentioned
~rCastle Crate" design, there is no need for any additional structure
extending up from the rail 106 or from the central portion of the floor
104.
The rail 106 in turn comprises a band 124 having vertical inner
and outer walls 126, 128 and a flange or lip 130 at the top thereof
extending out a slight distance therefrom. The end corners of the
band 124 and lip 130 are smoothly rounded. The vertical orientations
of the inner and outer walls 126, 128 are shown in cross section in
Figures 7, 10, 11, and 14. Since the outer wall 128 does not angle or
flare, the overall dimensions of the tray 100 are kept to a minimum --
about the same as that of a corrugated case. The tray 100 preferably
has a total height of 2.000 inches, a width (as viewed in Figure 2) of
10.750 inches and a length of 16.125 inches. The band 124 has an
undulating or curving configuration having cylindrical, smooth sur-
faces 132 on inner wall 126 adjacent to and above each perimeter
fluid container support area 114 and corresponding to the rounded
sides of the containers 102 to be supported on the areas. The floor
104 also has an undulated perimeter design curving outwardly at loca-
tions 134 at each outer fluid container support area 114 for conform-
ing generally to the cylindrical configuration of the bottom portions
of the fluid containers 102.
The columns 108 extend upwardly from the floor 104 to the rail
106 and between each of the support areas 116 where the undulating
perimeter curves in at location 136. These columns 108 are each
formed as a generally truncated conical member defining a vertical
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Figure 14 is an end elevational view, with portions thereof bro-
ken away, of the first tray in a loaded and stacked position.
Figure 15 is a top perspective view of a second tray of the
present invention.
Figure 16 is a top plan view of the second tray.
Figure 1~ is a bottom plan view of the second tray.
Figure 18 is a side elevational view of the second tray.
Figure 19 is an end elevational view of the second tray.
Figure 20 is a cross-sectional view taken along line 20-20 of
Figure 15.
Figure 21 is a cross-sectional view taken along line 21-21 of
Figure 15.
Figure 22 is a cross-sectional view taken along line 22-22 of
Figure 16.
Figure 23 is a cross-sectional view taken along line 23-23 of
Figure 16.
Figure 24 is a top perspective view of the second tray shown in
an empty and nested position.
Figure 25 is a top perspective view of the second tray shown in
a loaded and stacked position.
Figure 26 is a top perspective view of a third tray of the
present invention.
Figure 2~ is a top plan view of the third tray.
Figure 28 is a bottom plan view of the third tray.
Figure 29 is a side elevational view of the third tray.
Figure 30 is an end elevational view of the third tray.
Figure 31 is a top perspective view of a fourth tray of the
present invention.
Figure 32 is a top plan view of the fourth tray.
Figure 33 is a bottom plan view of the fourth tray.
Figure 34 is a side elevational view of the fourth tray.
Figure 35 is an end elevational view of the fourth tray.
Figure 36 is a cross-sectional view taken along line 36-36 of
Figure 32.
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Figure 3~ is a side elevational view, with portions thereof bro-
ken away, of the fourth tray shown in an empty and nested position.
Figure 38 is a side elevational view, with portions thereof bro-
ken away, of the fourth tray in a loaded and stacked position.
Figure 39 is a top perspective view of a fif th tray of the
present invention.
Figure 40 is top plan view of the fifth tray.
Figure 41 is a bottom plan view of the fifth tray.
Figure 42 is a side elevational view of the fifth tray.
Figure 43 is an end elevational view of the fifth tray.
Figure 44 is a bottom plan view of a sixth tray of the present
invention.
Figure 45 is a side elevational view of the sixth tray.
Figure 46 is an end elevational view of the sixth tray.
Figure 4~ is a cross-sectional view taken along line 47-4~ of
Figure 44.
Figure 48 is a cross-sectional view taken along line 48-48 of
Figure 44.
Figure 49 is a schematic view illustrating the redoubt pattern
configuration of the bottom of the fifth tray.
Figure 50 is a fragmentary view of the fifth tray loaded and
stacked and in a locked relationship on a similar loaded lower tray.
Figure 51 is a view similar to Figure 50 but with the loaded and
stacked trays in an unlocked relationship.
Figure 52 is a perspective view of the fifth tray loaded and
cross-stacked on a pallet.
Figure 53 is a fragmentary top plan view of an alternative col-
umn design for any of the trays of the invention.
DETAILED DESCRIPTION OF PREF~RR~n
EMBODIMENTS OF THE INVENTION
A number of variations of the present invention are possible,
and some of them are illustrated in the drawings. This invention as
will be expl~ined can be adapted to hold generally any type of fluid
container and is especially adaptable for twelve-ounce metal cans and
two-liter PET bottles, and particularly those with vertical side walls.
2 Q ~ 9 ~ 8 2
It can hold the containers (cans) in six packs or in~ividually. A first
preferred tray emhor~iment of the present invention is shown in Fi~
ures 1-14 generally at 100. Tray 100 is PCpeci~lly adapted for holtling
twelve-ounce metal cans, such as are typically used for soft drinks
and beer and shown for eY~mple in Figure 14 at 102. Tray 100 will be
described in greater detail than the other trays, and the description
thereof for cGI~F~l~or~ nc parts can be referred to for the other late~
described tray embo~iments. Tray 100 and the other trays herein
uniquely not only support the product therein over the entire tray
height, but also nest compactly one within the other when empty.
Tray 100 is integrally molded from a plastic, such as a high
density polyethPIene, which is a standard container material, and in a
sturdy, open light weight construction. Tray 100 comprises four basic
corr ponent_, namely, a floor 104, a rectangular rail 106 spaced above
and generally parallel to the floor, a plurality of colllmnc 108 extend-
ing between and interconnecting the floor 104 and the rail 106, and
support posts 110 at each of the four cGrnt:.s of the tray 100 intercon-
necting the rail 106 and the floor 104 and providing additional corner
support for the tray 100. These corner support posts 110 are, how-
ever, not required for this invention as will be apparent from some of
the other emho~liments described later herein.
The floor 104 has an upper surface 112 defining a plurality
(twenty-four) of fluid container support areas 114 for supporting
thereon the fluid containers 102. Each support area 114 is generally
2.650 inch square. The floor bottom surface 116 has a plurality of
receiving areas 118 for receiving thereon the tops of similar fluid
containers in a layer in a similar tray directly beneath the floor, as
depicted in Figure 14 generally at 120 by a similar (identical) loaded
tray. It is also within the scope of this invention to provide a plural-
ity of beveled redoubt members positioned and spaced on and extend-
ing down from the floor bottom surface 116,i as will be described
later in greater detail with respect to the tray (502) of Figures 44-51.
These beveled redoubt meml~ers provide a sliding surface so that tray
100 when loaded can be easily slid along the lips of the can tops of a
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slot 138 disposed outwardly relative to the floor 104. The inwardly
disposed surfaces of the columns 108 have three faces, each of which
angles upwardly and outwardly from the floor to the rail. The middle
face 140 is flat, and the outer two faces 142, 144 are generally
sidewardly oriented and have truncated conical configurations. The
configuration of these faces can be seen, for example, in Figures 1, 6,
~, and 8. Surface face 142 as shown in Figure ~ is preferably con-
structed from a cone having a base radius of 1.300 inches, an incline
of ten de~ ,ees per side and a wall thickness of .100 inch. The inward
surfaces of the columns 108 are thus generally conically shaped,
angling towards the longitudinal center line thereof, and the cans 102,
even when held loose, do not contact the immediately adjacent col-
umns even during normal transport movement of the tray 100. The
slots 138 are correspondingly configured to receive up thereinto the
inner surfaces of columns of another tray as shown in Figure 13, to
provide a deeply nested arrangement. Each additional empty tray 100
then adds only the narrow height of its rail 106 to the stack of empty
nested trays therebeneath, which additional height is only about
three-quarters of an inch, as can be understood from Figure 13, for
example.
The corner support posts 110 also angle inwardly and down-
wardly and have conical outer and inner surfaces 145, 146 (same as
the columns--see Figure 9) to slide along and relative to one another
when the trays are sliding into and out of their empty nested position
which is depicted in Figure 13.
The upper floor surface 112 can be smooth and planar across its
entire exrance. Alternatively, it can have indents or recessed areas
at each of the support areas 114 for receiving therein the bottoms of
each of the fluid containers 102; or it can have low-height divider ribs
on the surface thereof, separating the support areas 114 as will be
expl~ined later with reference to Figures 31-43.
A preferred design is to mold the floor 104 with a gridwork-like
configuration having a pattern of open spaces therethrough, as shown
in Figures 1-3 (and 26-28), so that less plastic floor material is needed.
The floor 104 is thereby made cheaper and lighter, and an attractive
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13
design is thereby presented. Any liquids, such as condensation, rain
water or beverages le~king from damaged containers, can drain
therethrough. This gridwork-like design preferably comprises a plu-
rality of circular members 148, one for each support area 114. Each
of these circular members 148 is slightly sm~1ler than the bottom of
the fluid containers 102 to be supported thereon. A plurality of radial
struts 149 extends radially out from each of the circular members 148
to suspend or support them. The circular members 148 are arranged
in rows and columns to thereby define one or more arrays, as illus-
trated in Figure 2 for example. In the preferred design of Figures
1-14 (and 26-30) there are four two-by-three arrays to accommodate
four six-packs of cans; in other words, there are twenty-four support
areas 114 in a four-by-six arrangement. The circular members 148
form a strong support structure and make it relatively easy to count
the number of support areas 114 in an empty tray 100 and also to posi-
tion the fluid containers 102 on the floor 104.
The gridwork floor 104 also comprises a plurality of longitudi-
nal and lateral struts 150, 152, extPn-ling (discontinuously) the full
length and width, respectively, thereof and between the rows and
columns of the circular members 148. The radial struts 149 then
extend to or through these lateral and longitudinal struts. At the
intersections of the longitudinal and lateral struts 150, 152 smaller
circular memhers 154 are formed and are thereby positioned in the
center of a square of the larger circular members 148 as can be seen
in Figures 2 and 3, for example. One interesting pattern extends the
central longitudinal strut 150 through each of the smaller circular
members 154 except for the center one 156 (Figure 12) and the cen-
tral lateral strut 152 through the centers of each of the smaller circu-
lar members 154 except for the center one 156, and the reln~ining
smaller circular members 154 then are fully open.
The floor bottom surface 116 is recessed upwardly at each
receiving area 118 for receiving thereinto the tops of fluid containers
102 in a layer in a tray 120 beneath the floor 104 in a preferred design
of this invention. These recessed receiving areas are shown for
example in Figures 3, ~, and 13, and can be understood from
2~19f.~
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comparing the tops of the bottom left two cans with the right two
cans in Figure 14. Each recess 158 is formed simply by having the
bottom surfaces of radial struts 149 angling from locations 158 (Fig-
ures 3 and 7) spaced a slight distance from the larger circular mem-
bers 148 to the larger circular members and locations 160 (Figures 3, 6
and 12) spaced from circular members 154. Any similar construction
for holding the floor bottom surface 116 to the tops of a bottom con-
tainer layer therebeneath, as would be apparent to those skilled in the
art, to prevent free sliding is within the scope of this invention.
Looking at the ends and sides of the tray 100, it is seen that the
areas between adjacent columns 108 and the floor 104 and the rail 106
define open spaces 162. This design requires less plastic then a more
solid design and thereby forms a tray which is lighter, cheaper and
more attractive. It further allows the fluid containers 102 therein to
be more completely seen, especially when loaded or partially loaded
trays are stacked one on top of the other, as depicted in Figure 14.
An alternative design of the present invention uses a "solidl'
floor configuration instead of the open gridwork-like design of tray
100. A solid design is illustrated by the tray shown generally at 200 of
Figure 15, for example, wherein a plurality of circular recesses 202 is
formed in the upper surface of the floor 204 for receiving therein the
bottom edges of the fluid containers or metal beverage cans 206.
When viewed from the top as in Figure 16 an array of rings is thereby
defined. From the sides as shown in Figures 18 and 19, the perimeter
of the floor 204 then is similar to the configuration of the floor 104 of
tray 100 and comprises a series of arcuate surfaces 210. The bottom
surface of the floor 204, as shown in Figures 17 and 22, has circular
recesses 216 formed up thereinto for receiving therein the top rims of
the cans 206 and thereby preventing free sliding of an upper loaded
tray 200 on a similar bottom loaded tray as shown generally at 218 in
Figure 25. Tray 200 similarly has a rail 220, and angled columns 224
between the arcuate surfaces 210 and defining outward slots 226.
Although tray 200 is not shown to have corner support posts, it is
within the scope of this invention to provide such support posts for
the Figure 15 embodiment, similar to those shown in Figure 1.
2Q19~i~2
- 15
The tray as shown generally at 300 in Figures 26-30 is, gener-
ally spe~king, a cross between trays 100 and 200. It has the gridwork-
like floor 302 of tray 100 and like tray 200 does not have any corner
support posts. Similar to trays 100 and 200 it has a rail 304 and angled
columns 306 defining outwardly-disposed receiving slots 308. Thus,
the tray 300 of Figure 26, for example, can receive therein loose (or
packaged as with a thin plastic film or an upper plastic holder) cans
or similar containers in an array, such as a four-by-six array, and hold
them securely, preventing them from tipping or rubbing against each
other even during the movements normally associated with the trans-
port and h~n~lling thereof. The trays 300, when loaded, also securely
stack one on top of another as can be understood from Figure 25. The
trays 300 when empty can be nested one on top of the other for stor-
age or transport, and similar to trays 100 and 200, each empty tray
300 adds only the narrow height of its rail 304 to the stack of empty
trays when nested therein.
The general concept of this invention can be easily adapted for
h~n-lling other containers of different sizes and shapes. An example
is illustrated in Figures 31 through 43 for two-liter PET bottles, such
as are shown at 400 in Figure 38, wherein two embodiments are illus-
trated, the first shown generally at 402 in Figures 31 through 38 and
the second shown generally at 404 in Figures 39 through 43. The only
difference between them is the inclusion of the corner support posts
406 in the embodiment of Figure 31. The posts 406 serve a similar
outer support function for the overhanging support area corners of
the floor 407.
Longitudinal and lateral divider struts 408, 409 extend across
and along the floor 407 to separate the individual support areas 410
from each other, to hold the bottles 400 better in place and to pre-
vent them from tipping. As can be seen, the three lateral divider
struts 409 are taller than the single longitudinal strut 408. This hold-
ing function is more important for the plastic bottles 400 than it is
for the can trays 100, 200, 300 because of the greater likelihood that
the tall, flexible bottles 400 will buckle if they tip when stacked. The
trays (or carriers) 402, 404 of Figures 31 through 43 are designed to
-- 201~2 - 16
support and carry eight bottles 400. lt is, of course, within the scope
of the present invention to size the trays 402, 404 differently to carry
either more or fewer bottles, and/or bottles or other containers of
different sizes and/or shapes.
The bottom tray surfaces 411 are recessed in with rounded con-
figurations, such as is shown in Figures 37 and 38 by the recess areas
412, to receive up thereinto the caps 414 of the bottles 400 on a lower
tray as shown generally at 416. This prevents the upper loaded tray
402 from freely sliding along the top of the bottles in a tray 416
beneath it and makes it less likely that the bottles in the lower tray
416 will tip. When in an empty nested arrangement, the upper tray
fits into the lower tray so that the rail lip 418 of the lower tray is at
the bottom of the rail or band 420 of the upper tray, as best shown in
Figure 37. As can be appreciated from Figures 31 and 39, the areas
between adjacent columns 422 or columns 422 and adjacent posts 406
and between the floor 408 and the rail 420 define open spaces 424 for
reasons discussed above relative to trays 100, 200 and 300 and allow
the bottles 400 therein to be easily seen from the sides. The bottles
400 can thus be identified as to type, easily and readily seen to deter-
mine whether the tray is fully loaded, and more fully displayed in a
retail setting.
Another carrier, crate or tray of the present invention, which
is particularly configured for h~n-lling today~s rimmed metal cans such
as shown in Figures 50-52 at 500 (or at 102 or 206), is illustrated in
Figures 44-48 generally at 502 and is further expl~ined by reference
to Figures 49-52. Tray 502 is the same as tray 100 except for the con-
figuration of the bottom surface 504 of the floor 506. The top surface
507 of the floor 506, the columns 508, the rail or top band 510 and the
corner support posts 512 correspond to those of tray 100. Further
discussion of the construction and advantages of the corresponding
elements and the bottom surface 504 follows.
The top band 510 is not only for tray stacking purposes and for
holding the top of the tray 502 in a rectangular configuration, but by
going in and out and following the shape of the cans 500 for a certain
length of the can side wall arc, it also thereby contacts, supports and
2 0 1 9 5 $ rJ
locates the cans within the tray. The cans 500 when supported on the
floor 506 will touch the side wall of the band 510 along the arcuate
portions 514 thereof, as shown in Figures 4~ and 48. That is, there is
a surface-to-surface contact laterally supporting~the cans 500. The
cans 500 then will exert a generally horizontal load against the band
510, and thus this undulating surface or corrugation beneficially
makes the wall of the band S10 stronger, more rigid and less likely to
be deformed. When molding parts with large numbers of surfaces, it
is preferable to not have any of those surfaces comprise long, flat
walls since it is difficult to control their shape. Thus, a side wall
formed by changing surfaces, as is the present top band 510, tends to
be more rigid. Although theoretically there must be some minimum
clearance between the cans S00 and the case or tray 502 so that the
cans can actually be fitted into the case, once they are in place, they
can be touching on all sides and, in fact, will be touching on various
sides at any given time.
There is no significant taper to the side walls of the top band
510. Their only taper is a nominal one-quarter degree "taper" merely
enough so that the trays 502 can be removed from their molds. These
vertical walls allow the trays 502 to support the cans 500 (or bottles)
throughout the entire height of the band 510. The support surface
(514) follows the shape of the can 500 and is vertical like the shape of
the can, and there is thus complete contact between the can and the
side wall of the band 510 at a height that is at the highest point of the
tray 502. The side wall is thereby effective for its entire height, and
the open can label exposing area 516 between the floor 506 and the
rail 510 can advantageously be made larger. Since only the small
thicknP-ccp-c of the rail walls are added to the tray length and width
dimensions beyond that of the layer of cans, the trays can cross-stack
effectively, as illustrated in Figure 52. Nestable plastic trays with
short slanted side walls, which have recently been made available by
others, also have the significant slants of their walls added to their
effective dimensions, and cross-stacking patterns for them thus do
not work well, if at all.
2 û ~ 3 . ~ ! ~
-- 18 --
The columns 508, in addition to their nestability function, must
also be substantial enough to support the top band 510 so that the
carrier or tray 502 does not break apart when the cans 500 push
against the top band. The columns 508, by following the shape or con-
tour of the cans, provide substantial structural support. Their pyra-
mid design allows them to have the largest area at their bottom, mak-
ing it unlikely that they will be torn away from the floor 506 in the
event of a severe impact. The present tray 502 thus effectively uti-
lizes the area between the cans 500 to create substantial columns 508,
which do not contact and thereby scratch the cans during normal tray
h~n~lling.
Alternatively, columns 508 at their maximum size can exactly
conform to the shape of the bottom of the can 500 and then taper
away at an angle that allows the trays to nest. As shown in Figure 53,
the columns 508 can be two-sided, and their two faces 520, 522 meet
at a tangent point 524 in between the cans (500). In other words, the
two arcs that form the bottom of the conical areas can be extended
through the middle towards the center of the tray (502) where they
meet. The cans (500), however, are not dropped into the tray (502)
directly from above, but rather are fed in at an angle during normal
loading procedures. The cans also sometimes have a secondary wrap,
such as a six-pack wrap, on them hol~ling them together, so the col-
umns should not go too far into the tray to interfere with the wrap.
The previously tli.s~lnsed~ three-sided colllmn design (see, e.g., 140, 142
and 144) better Pnabl~ the cans to be fed in at an angle so that they
do not strike the columns during loading and also to not interfere with
any secondary wrap.
With todayls high-speed C~nning machinery used to palletize or
build a pallet load of can trays, it would be difficult to work with the
present tray 502, which is fabricated of a material with a low coeffi-
cient of friction, if some means were not provided to give the tray an
inherent ability to locate itself properly on a lower tray. The stacked
and/or cross-stacked trays 502 of cans 500 on a pallet 526 need to be
aligned vertically, not for load-bearing reasons, but to build a proper
"square" load on the pallet for stability as well as efficient use of
- 2Q19~2
19
space in trucks and warehouses. A redoubt pattern shown generally at
530 is accordingly provided on the floor bottom surface 504. Once
palletized, the trays 502 remain in position, safely locked in by the
redoubts 532, during in-house movements by fork lifts, as shown in
Figure 52 at 534, or by truck transport. Unlike glass bottles, trays of
cans are able to withstand vertical loads from upper trays irrespec-
tive of whether or not individual cans are or are not directly above or
below one another. This is because the top rim 535 of a can 500,
unlike the tops of bottles, approximates the same diameter as the can
body and the cans are packed tightly together in the tray.
Delivery route drivers need to be able to easily remove individ-
ual trays of cans from a pallet load or a stack of trays, sometimes
reaching up overhead to do so, as they make their deliveries. In most
cases, lifting a prior art tray of cans up off a lower tray is difficult
and can subject the delivery person to a risk of injury. The present
tray 502 because of this redoubt pattern 530 only requires that the top
loaded tray be twisted about a vertical axis a small amount of
between two and eight degrees, or more particularly five degrees, to
cause the top tray to contact the rims 535 on can tops below on the
non-recessed redoubt member surfaces 536 only, as can be understood
by comparing Figures 50 and 51. The upper tray can thus slide
unimpeded across the lower tray to its new position.
The area in which the redoubts can be positioned is the area
that is not occupied by the cross-stacking clearance needed between
can rims 535. Thus, the flat recessed area 538 determines where the
redoubts 536 can be placed or positioned, and everything that is not
flat recessed can be a redoubt. The recessed area 538 can theoreti-
cally simply take the shape of the rim 535 and occupy the same area
as the rim. However, since the cans (500) do not line up directly
under each other and move around during h~n~lling, they are not
equally spaced. The side walls (510) of the trays also add up in a
cross-stacked configuration to cause the cans to shift a slight distance
relative to cans above them. Thus, a certain tolerance or clearance
between the redoubts 536 is required. A preferred design approach,
as depicted in Figure 49, models the recessed area pattern on the
2~19~g~
- 20 -
computer from an exact rim pattern 539 as shown by the right hatch
marks, adds an extra sixteenth or eighth of an inch clearance width
540, as shown by the dotted lines, to that recessed area and then
forms the redoubts 536, as shown by the left hatch marks, in circular
and diamond shapes around them. The redoubts 536 depend down
between .025 and .100 inch or approximately .050 inch from or rela-
tive to the recessed areas 538 (or 539 plus 540).
This design approach thereby positions some 541 of the
redoubts inside the rims 535 and some 542 outside the rims or intersti-
tially between a square of cans. Pull-top ~ minllm cans 500 have
open top rims 535 and not just top surfaces as do bottle closures. This
allows the redoubt members 536 to also be located within the rims 535
where the members can have a round or disc shape, interstitially
between the cans, or both. The redoubt pattern of the '039 applica-
tion positions the redoubts only between the can rims. However, it
has been found that the cans move around more than originally
expected, thus requiring larger recessed areas 538. Larger recessed
areas 538 necessarily decrease the size of the redoubts 536. With the
number of redoubts 536 remaining constant and their sizes decreased,
the amount of total redoubt surface area per tray 502 shrinks. Addi-
tionally, the bottoms 504 of the trays 502 are subjected to consider-
able wear, as when the loaded trays are slid along a concrete floor or
when they are running on conveyors, and the reduced redoubt surface
area was found to wear out too quickly. The present redoubt pattern
530 with additional redoubts 541 inside of the rims 535 significantly
and advantageously increases the total redoubt surface wear area,
thereby exte~iing the useful life of the tray 502. The locking and
unlocking functions of the rim 535 inside and outside redoubt members
535 are the same. If there were no wear problem, then only the inside
or the outside redoubt members 541 or 542, and not both, would be
needed.
The bevel along the perimeter edges 542 of the redoubt mem-
ber 535 is the same whether it is on the inside or the outside of the
rim 536, and has an angle of between twenty and thirty degrees. Its
purpose is to ride the rim 535 off, to have some locking ability yet to
2 ~
- 21 -
be able, with a slight twist of the tray 502, to ride all of the cans off
and allow the tray to slide. Thus, with the trays loaded and stacked,
the top tray needs to be twisted only approximately five degrees, to
shift it so that all the can rims 535 are on the bottom surfaces of the
redoubt members 536 and therefore are not locked in. The redoubts
536 enable an upper tray to slide easily over a lower tray once the
~lock~ between them is broken by this twisting step, as can be under-
stood from Figure 51.
When the trays are cross-stacked or otherwise oriented in dif-
ferent directions, the two wall thickness shifts add up towards the
center of the pallet. The shift pushes the cans out in different direc-
tions so that they do not line up precisely one on top of the other. As
previously stated, the length and width of the present tray is very
close to the length and width of the layer of twenty-four cans since
the shift resulting from the thin vertical walls is quite small. With a
tapered side wall, the shift is equal to the thickness of the wall plus
its taper. Since the shift of the slanted wall trays is larger than that
of the present tray, the ability to position redoubts on a slanted wall
tray is limited, as larger recessed areas neede~ As the recessed areas
increase in size the redoubt area must necessarily decrease. At a
certain point the redoubts become ineffective as they are too small
and thereby wear off early in the life of the tray. This is not a prob-
lem, however, with the present vertical wall tray design.
The columns of any of the trays 100, 200, 300, 402, 404 or 502
can be understood or described in either of two ways. One way is that
they extend only from the bottom surface of the floor, up to the lower
edge of the rail or band, as can be best appreciated from an outside
side view especially when in an empty nested arrangement. Thus, the
band extends continuously the entire circumference of the tray and
includes the upper extensions of the slots of the columns. Another
way is that the columns themselves extend all the way to the top of
the rails or to the lip, which is better appreciated when looking at the
inside of the trays such as shown in the empty perspective views. In
the latter case, the band can be considered to comprise a plurality of
band segments extending between adjacent coll~mnc. Either way an
2~e3~3
~ 22
improved sturdy compact tray which is inexpensive to manufacture
and handle is defined. This tray when empty is easily and deeply
nestable one within the other without any undue manipulation or ori-
entation thereof. The tray has an attractive and open design allowing
the containers therein to be fully displayed. The tray has minimum
width and length dimensions allowing for effective cross-stacking
conf igurations.
From the foregoing detailed description, it will be evident that
there are a number of changes, adaptations and modifications of the
present invention which come within the province of those skilled in
the art. However, it is intended that all such variations not departing
from the spirit of the invention be considered as within the scope
thereof as limited solely by the claims appended hereto.
