Note: Descriptions are shown in the official language in which they were submitted.
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
METHOD AND APPARATUS FOR PACKING AND
BI-DIRECTIONAL COOLING OF PRODUCE
FIELD OF THE INVENTION
The present invention relates to an improved method for the improved
to packing, cooling, storage, and shipping of produce. More particularly, the
present
invention utilizes a flow of cooling air introduced into an improved container
system
comprising vacuum formed fruit containers received into and in operative
combination with an improved tray design. More particularly still, the flow of
cooling
air enabled by the present invention may be in more than one direction
relative to the
15 container system.
BACKGROUND OF THE INVENTION
Many produce products are harvested and paclced in the field into containers
which are ultimately purchased by the end consumer. Examples of such produce
20 items include, but are not limited to, tomatoes, berries, grapes,
mushrooms, radishes
and broccoli florets. Many of these produce items require substantial post-
harvest
cooling in order to enable shipping over long distances and to prolong shelf
life.
In use, a grower's harvesting crew harvests produce items of the type
previously discussed directly from the plant in the field into the container.
The
25 containers are then loaded into trays, which contain a specific number of
individual
containers and the trays, when filled, are loaded onto pallets. The most
common
pallet used in the produce industry in the United States is the forty by forty-
eight inch
(40" x 48") wooden pallet, and the vast majority of produce handling, storage
and
shipping equipment is designed around pallets of this size.
3o After the pallets have been filled and loaded in the field, they are
transported
to shippers who perform a variety of post-haxvest processes to enhance the
marketability of the produce itself. For manly types of produce, including
berries, a
significant packing evolution is the post-harvest cooling of the packed fruit.
Indeed,
berry shippers are often referred to as "coolers". The process of cooling
berries
35 typically includes injecting a stream of cooling air into one side of a
tray and thence
through the individual baskets and around the berries stored therein. As the
air cools
-1-
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
the berries, it picks up heat therefrom which is exhausted from apertures on
the
opposite side of the tray.
Packages for use by berry coolers have undergone a systematic process of
evolution to improve the storing and cooling of the fruit while reducing
packaging
costs. While early berry packaging products included the use or folded wood or
chipboard containers, a common package for the marketing of strawberries for
instance, is a one pound vacuum formed plastic basket developed in conjunction
with
Michigan State University. This one piece package, hereinafter referred to for
brevity
as a "Michigan basket", includes a basket body formed with an integral hinged
lid
l0 which, after the basket is filled with fruit, is folded over and loclced in
place with
respect to the basket body. The lid is retained in position by means of a
detent, which
engages an edge flange of the basket body. Disposed at or near the
substantially flat
bottom of the basket body are a plurality of apertures, typically elongate
slots, to
provide air flow through the body of the packed fruit in the baslcet. This air
flow
continues through a similar series of apertures formed in the lid. In the case
of the
strawberry package, typically, eight (8) sixteen ounce (16 oz) baskets are
loaded into
a formed and folded corrugated cardboard tray.
The tray developed for use with the Michigan basket has one or more
openings along either of its short ends to enable air flow through the tray.
From the
previous discussion on berry cooling, it will be appreciated that in the
typically
formed strawberry package system in current use, the two individual baskets
within
the tray which are immediately adjacent to the air intake apertures formed in
the ends
of the tray receive substantially more cooling from air inflow than do the two
packages at the discharge end of the tray. To overcome this deficiency in air
flow,
berry coolers are currently required to utilize substantial amounts of cooling
energy to
ensure that fruit packed at the discharge side of the tray receives sufficient
cooling to
prolong its shelf life, while precluding the freezing of berries at the intake
side of the
tray.
The previously discussed problem is due to the fact that the one pound
3o strawberry baskets and the tray which contains it were developed
separately.
Specifically, the design of the previously discussed one pound strawberry
basket was
finalized prior to the design of the tray which ultimately receives eight of
these
baskets therein. The previously discussed one pound strawberry containers in
current
use measure approximately four and three quarter inches by seven and one
quarter
2
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
inches (43/4" x 71/4") and are three and one half inches (31/Z") tall with the
top secured.
As a result, the commonly used eight basket tray measures approximately
fifteen and
one-half inches by nineteen and three quarters inches (151/2" x 193/4"). This
tray size is
to some extent mandated by the size of the baskets it contains. While no great
difficulty was likely encountered in forming a tray to fit a given number of
the
baskets, the area or "footprint" of the resultant tray was not given
sufficient
consideration in the design of the baskets. This has given rise to a
significant
inefficiency of packaging.
Because the current eight - one pound strawberry trays, and the baskets
l0 shipped therein are not fitted together properly, the package does not
fully utilize the
surface area of a forty by forty eight inch pallet, therefore shipping of
those pallets is
not optimized. Specifically, using current basket technology, a layer of
strawberries
comprises six (6) trays per layer on the pallet. With eight (8) one pound
baskets per
tray, this means that forty eight pounds of fruit can be packed per layer on a
standard
40 inch by 48 inch pallet. Because there is no way with current use packages
to
completely fill the pallet with trays, a significant portion of the pallet
remains unused.
This of course forms a further inefficiency of shipping.
Another problem with current use plastic produce baslcets is that they are
usually formed with vertical stiffening ribs. This is done to maximize the
resistance
of the relatively thin basket to deformation. These ribs also provide salient
intrusions
into the body of the basket. Where a pulpy fruit, such as berries, are packed
in the
basket, handling shock to the packed fruit, combined with the fruit's own
weight turns
these intrusions into sites where significant bruising of the paclced fruit
occurs. This
loss of fruit quality results in higher costs the shipper, transporter,
retailer and
consumer alike.
The previous discussion has centered on the specific case of the one pound
whole strawberry container preferred by consumers. It should be noted,
however, that
while strawberries comprise the bulk of all U.S. berry consumption, other
berry crops
also enj oy a significant position in the marketplace. Each of these berry
crops has, to
3o a certain extent, given rise to preferred packaging embodiments therefor.
By way of
illustration but not limitation, while strawberries are typically sold in
eight ounce or
one pound containers, blueberries are typically sold by volume, specifically,
consumers tend to prefer the one pint package of blueberries. Raspberries, on
the
other hand, are typically marketed in small five or six ounce trays.
3
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
The trays into which each of these differing types of berry baskets are
ultimately installed have not been designed with a view to integrating them
with other
berry or indeed other produce crops. This presents a problem to the small-to-
medium
sized grocery establishment which may not order berries in multiple pallet
lots but
may prefer, for various reasons, to mix quantities of berries on one pallet.
Because
the trays used in the several aspects of the berry industry are not integrated
one with
another this capability is, at present, not realized. Accordingly, smaller
lots of berries
as commonly shipped to small-to-medium sized grocers must typically be sold at
a
premium cost in order to compensate the grower, shipper and transporter for
the
packing and shipping inefficiencies occasioned by the lack of packaging design
cohesion.
Another problem with the previously discussed Michigan basket is the latch
which retains the lid in the closed position with respect to the body. The
Michigan
basket uses a single detent formed in the lip of the lid to engage the edge of
the basket
body lip. This latch arrangement has proven troublesome in that it is
difficult to
quickly and securely close in the field while being prone to unwanted opening
during
packing, shipping and while on the grocer's shelves.
Other workers in the packaging arts have attempted to solve the previously
discussed latch deficiencies by means of forming snap fasteners in the edge
material
2o of the plastic baskets which they produce. The results obtained by this
design are
mixed. While the snap fasteners may be slightly more secure than the
previously
discussed edge latch, they are at least as difficult to align properly by
pickers in the
field as the Michigan basket latch.
The trays currently available for use with Michigan baskets designed for one
pound strawberry packing are not generally well suited for the baskets in that
the
baskets axe allowed considerable freedom of movement within the trays. This
results
in an increased incidence of shifting of the baskets within the trays, which
causes an
increase in bruising of the fruit stored in the baskets.
Another problem not contemplated by the prior art is that different
quantities,
types, and external forms of produce a require different cooling air flow
regimes.
Some combinations of fruit types and quantities benefit from the relatively
laminar
flow provided by the invention of U.S. Patent No. 5,738,890. Further research
has
shown that some combinations of produce quantity and type benefit from a
relatively
turbulent air flow through the basket during the cooling process.
4
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
Finally, while the inventions taught and claimed in U.S. Patent Nos.
5,738,890, 6,074,676, and 6,074,854, incorporated herein by reference, provide
hitherto unmatched cooling for produce items, they require that the containers
all be
aligned alike with respect to the flow of cooling air. See for instance Fig. 8
of U.S.
Patent 6,074,854. Where the containers in one layer on a pallet are aligned
perpendicular to one another, the flow of cooling air is interrupted. One
example of
such pallet loading is "5-down" or "10-down", an example of the former being
shown
at Fig. 8 herewith.
What is clearly needed is an improved berry packing system which will
to significantly reduce the cooling time and cooling expense for the fruit
contained in the
baskets. To make such an improved system feasible, it must interface with
commonly
used and preferred materials handling apparatus, specifically the previously
discussed
forty by fot-ty eight inch pallets in current use in the grocery industry.
Moreover,
where a different pallet size has been adopted as standard, for instance in
another
15 country, what is further needed is a system which can be scaled to effect
the
advantages hereof in that pallet system.
The baskets of such a system should be capable of being formed in the
preferred size or quantity configuration preferred by the end consumer, while
simultaneously maximizing their footprint on existing pallet technology. The
baskets
20 should be formed to minimize bruising and other damage to the fruit packed
therein.
Furthermore, such a system should provide for the mixing of lots of different
types,
quantities and sizes of produce on a single pallet without substantial losses
of
packaging efficiency occasioned by differing types of misaligned trays.
The basket should possess a lid latch capable of being quickly and securely
25 fastened in the field. The same lid should be capable of being repeatedly
opened and
closed during packing, while on the grocer's shelves and ultimately by the end
consumer.
The packaging system should enable the packaging of one layer, or a plurality
of layers of filled baskets therein.
3o The several components of the packaging system should be capable of
providing cooling air flow regimes relatively optimal for the type and
quantity of
produce to be stored in the baskets.
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
Finally, the system should enable the placement of trays substantially
perpendicular with one another while still enabling the previously discussed
cooling
advantages.
If possible, the system should be formed utilizing existing equipment and
machinery from materials of the same or lesser cost than currently available
fruit
packages.
SUMMARY OF THE INVENTION
The present invention implements packaging systems such as the MiximTM,
to MiximPlusTM, MiximSDTM or MiximlODTM packaging systems, each available from
Plexiform Inc., of Watsonville, CA, which system comprises an improved produce
packing system which matches trays with baskets to significantly reduce
cooling time
and expense for the fruit contained in the baskets. This is done by several
means.
First, cooling channels may be formed in base of the individual baskets. These
15 channels may be aligned with apertures formed in the sides of the trays
into which the
baskets are loaded. Second, the lid, when closed over the basket body defines
at least
one, and preferably a plurality of horizontal slots. These slots, in
combination with
other apertures formed in both the basket body and lid significantly improve
air flow
through the basket. The size, number and extent of the horizontal slots and
their
2o respective vertical positions on the basket may be arranged to optimize
cooling for the
type and quantity of produce for which the basket is formed.
Thus, the combination of basket horizontal slots, apertures and the cooling
channels aligned with tray apertures provides a significantly improved flow of
cooling
air flow through the berries. This improved air flow results in improved
cooling
25 efficiency and hence lower paclcing cost, resulting in a better quality
berry, having a
longer shelf life, and delivered to the consumer at a lower cost.
The cooling air flow provided by the several embodiments of the present
invention may be optimized for generally laminar cooling air flow, relatively
turbulent air flow, or some combination thereof. Tlus is accomplished by
selecting
3o cooling slot geometries and tray configurations which provide the desired
air flow
regime.
The packing system of the present invention interfaces with commonly used
and preferred materials handling apparatus, specifically the forty by forty-
eight inch
pallets in standard use in the grocery industry. The trays of the present
invention are
6
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
designed to completely fill either standard or custom pallets in a number of
stack
configurations, including the previously discussed 5-down and 10-down stack.
This
results in significant improvements in shipping efficiencies, again lowering
costs to
the consumer.
The baskets of such a system are capable of being formed in the preferred size
or quantity configuration preferred by the end consumer, while simultaneously
maximizing their footprint on standard pallets. Thus, the system provides for
the
mixing of lots of different types, quantities and sizes of produce on a single
pallet
without any of the substantial losses of packaging efficiency occasioned by
packing
to differing types of misaligned trays. This advantage is accomplished by
utilizing trays
of the same area, but which may differ in their vertical dimension. The
different trays
required for different fruits, as taught by the present invention, not only
possess the
same footprint, but the same lug configuration as well. Accordingly, the
present
invention provides for the intermixing of different capacity trays on the same
pallet.
15 The only requirement is that trays in a given layer should all possess
similar heights.
The baslcets taught herein are formed to minimize bruising and other damage
to the fruit. In one embodiment, this is accomplished by designing the baskets
without vertical stiffening ribs or other salient intrusions into the basket,
but with
gentle curves on substantially all those surfaces which come into contact with
the fruit
2o packed within. This further minimizes costs and losses to the grower,
shipper,
transporter and retailer.
The baskets possess a lid latch capable of being quickly and securely fastened
in the field. The same lid is capable of being repeatedly opened and closed
during
paclcing, while on the grocer's shelves and ultimately by the end consumer.
25 The system is capable of being formed utilizing existing equipment and
machinery, and generally from materials of the same or lesser cost than
currently
available fruit packages.
The system enables the placement of trays perpendicular with one another
while still enabling the previously discussed cooling advantages.
3o Other features of the present invention are disclosed or appaxent in the
section
entitled "Detailed Description of the Preferred Embodiments."
7
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
BRIEF DESCRIPTION OF THE DRAWING
For fuller understanding of the present invention, reference is made to the
accompanying drawing in the following Detailed Description of the Preferred
Embodiments. In the drawing:
Figure 1 is a perspective view of one closed produce basket according to the
principles of the present invention.
Figure 2 is an end view of the closed produce basket shovnnz in Figure 1.
Figure 2A is an end view of an alternative closed produce basket according to
the principles of the present invention.
l0 Figure 3 is plan view of the open produce basket shown in Figure 1.
Figure 3A is a plan view of the open produce basket shown in Figure 2A.
Figure 4 is a perspective view of a tray as taught by the present invention.
Figure 5 is a perspective view of a plurality of closed produce baskets loaded
into trays as taught by the present invention.
15 Figure 6 is a detail of one lid detent of the produce basket posed prior to
closing the lid over the basket body.
Figure 7 is a detail of one lid detent of the produce basket after closing the
lid
over the basket body.
F figure 8 is a perspective view of a plurality of trays of the present
invention
2o shown loaded on a pallet in a 5-down configuration.
Figure 9 is a perspective view of a closed first alternative produce baslcet
formed according to the principles of the present invention.
Figure 10 is an end view of a. closed alternative produce baslcet formed
according to the principles of the present invention.
25 Figure 11 is a perspective view of a first alternative tray incorporating
flow
restriction tabs.
Figure 12 is a perspective view of a plurality of closed produce baskets
loaded
into the first alternative tray.
Figure 13 is a perspective view of a second alternative tray incorporating
flow
3o restriction tabs, and optimized for producing turbulent flow.
Figure 14 is a perspective view of a plurality of closed produce baskets
loaded
into the second alternative tray.
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
Figure 15 is a perspective view of a third alternative tray incorporating flow
restriction tabs, the tray further optimized for producing turbulent flow, and
for
receiving therein a plurality of layers of baskets.
Figure 16 is a perspective view of a plurality of closed produce baskets
loaded
into the third alternative tray formed to receive therein a plurality of
layers of baskets,
the tray being optimized for producing turbulent flow.
Figure 17 is a perspective view of a plurality of closed produce baskets
loaded
into a fourth alternative tray formed to receive therein a plurality of layers
of baskets,
the tray for providing relatively laminar air flow.
to Figure 18 is a perspective view of a plurality of closed produce baskets
loaded
into a fifth alternative tray formed to receive therein a plurality of layers
of baskets,
the tray for providing relatively laminar flow of cooling air.
Reference numbers refer to the same or equivalent parts of the present
invention throughout the several figures of the drawing.
9
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Having reference to Fig. l, a first preferred embodiment of the produce basket
1 of the present invention is shown. Produce basket 1 is a one-piece structure
incorporating both basket body 10 and lid 11. That portion of produce basket 1
joining basket body 10 and lid 11 is formed as a hinge, 12. Basket body 10 is
further
defines a transverse concavity defining channel 13. While a first preferred
embodiment is a vacuum formed plastic structure, the principles of the present
invention are equally applicable to alternative materials and manufacturing
technologies. In a first preferred embodiment of the present invention, the
basket is
1o formed of Kodapak~ PET Copolyester 9921, available from Eastman Kodalc.
Alternative materials include, but are not limited to various polymeric and
monomeric
plastics including but not limited to styrenes, polyethylenes including HDPE
and
LPDE, polyesters and polyurethanes; metals and foils thereof; paper products
including chipboard, pressboard, and flakeboard; wood and combinations of the
15 foregoing. Alternative manufacturing technologies include, but are again
not limited
to thermocasting; casting, including die-casting; thermosetting; extrusion;
sintering;
lamination; the use of built-up structures and other processes well known to
those of
ordinary skill in the art.
Continuing with this first preferred embodiment, and referring now to Figs. 6
20 and 7, each of basket body 10 and lid 11 has formed about the periphery
thereof a lip,
14 and 15 respectively. In a first preferred embodiment shown in Fig. 1, lid
11 is held
in the closed position by at least one set of paired, mating detent latches 16
and 17.
Latches 16 and 17 axe formed as substantially vertically protruding members
from lips
14 and 15 respectively. Latches 16 and 17 include teeth 18 and 19. When lid 11
is
25 closed over body 10, tooth 18 of latch 16 engages tooth 19 of latch 17, and
maintains
lid 11 secured in the closed position with respect to body 10. Teeth 18 and 19
are
maintained in the latched condition by the elastic deformation of latches 16
and 17.
In a first preferred embodiment, a pair of latches 16 and 17 are disposed
about each of
the front corners of basket 1. A third pair of latches 16 and 17 is disposed
about the
30 rear edge of basket 1. In this manner, lid 11 is secured to body 10 by a
plurality of
pairs of latches, acting in compressive opposition. This arrangement provides
a lid
closure which is at once more easily effected under field conditions, more
secure, and
may be more easily opened and resealed than previous fruit basket latches.
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
With continuing reference to Fig. 1 and also now having reference to Figs. 2
and 3, some of the improved ventilation features of this first preferred
embodiment of
the present invention are shown. Lateral ventilation channel 13 is formed at a
substantially lower portion of body 10. Channel 13 is disposed on body 10 to
provide
an improved flow of cooling air and ventilation through the lower portion of
body 10.
To accomplish this, at least one, and preferably a plurality of vent apertures
(not
shown in this figure) are defined within vent bosses 20. In order to provide a
similarly improved flow of cooling air and ventilation through the upper
portion of
body 10, vent slot 5 is defined when lid 11 and body 10 are secured together.
Slot 5 is
1o maintained at a fixed distance by paired detent latches 16 and 17. The flow
of cooling
air through the basket is further improved by at least one, and again
preferably a
plurality of vent apertures (not shown in this figure) in the upper surface of
lid 11. A
second vent slot, 5', is also formed when lid 11 and body 10 are secured
together.
Vent slot 5' is perpendicular to vent slot 5, and enables a similar flow of
cooling air to
be utilized in a direction perpendicular from the first flow of cooling air.
The upper and lower vent apertures, 22 and 21 are clearly shown in Fig. 3.
Also shown in this figure are the general arrangement of detent latches 16 and
17. In
a first preferred embodiment, lower latches 16 are disposed about a
substantially inner
portion of lower lip 14, while upper latches 17 are disposed about a
substantially outer
2o portion of upper lip 15. In this manner, when lid 11 is secured to body 10,
lower
latches 16 are substantially captured within upper latches 17, and maintained
in an
engaged configuration by the elastic deformation of latches 16 and 17 in
operative
combination with teeth 18 and 19 (not shown in this figure). Furthermore,
lateral
movement and potential disengagement of lid 11 from body 10 is substantially
precluded by latches 16 and 17 disposed about the portions of body 10 and lid
11
immediately adjacent to hinge 12.
With continued reference to Fig. 3., it will be apparent that in closing lid
11
onto body 10, latches 16 and 17 disposed about the portions of body 10 and lid
11
immediately adjacent to hinge 12 will be the first to engage as lid 11 is
closed. After
3o teeth 18 and 19 (not shown in this figure) of this latch pair engage, the
act of closing
lid 11 continues, and latches 16 and 17 at the front end of basket 1 are
engaged. The
operator, by applying further closing pressure, elastically deforms to some
degree at
least some of latches 16 and 17, engaging teeth 18 and 19 (not shown in this
figure)
and thereby securing lid 11 onto body 10.
11
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
While the preceding discussion regarding a first preferred embodiment has
centered on a one piece basket incorporating the basket body and lid joined by
a
hinge, it will be immediately apparent to those of ordinary skill in the art
that the
principles of the present invention may with equal facility be embodied in a
two piece
implementation utilizing a separate body and lid. This embodiment is
specifically
contemplated by the teachings of the present invention.
The preceding discussion details a first cooling regime wherein cooling air is
actively urged towards both channel 13 and vent slot 5 and/or 5'. It is
thought that this
cooling regime may result in a more laminar flow of cooling air about produce
to contained within basket 1. For some combinations of produce type and
quantity
however, a different cooling regime results in superior cooling. To produce
this
cooling regime, cooling air is actively urged ouy towards vent slot 13. It is
thought
that this results in a more turbulent flow of cooling air about the enclosed
produce,
and that cooled air exits both through vent channel 13 and the opposite end of
vent
slot 5 or 5'. This alternative cooling regime is provided by use of
alternative tray
designs, as described below, and may be accentuated by certain modifications
to the
basket design itself.
Continued research into produce cooling has shown that some produce
type/quantity combinations require different velocities of cooling air to
achieve
optimal cooling. This can be attained by altering the size of slot 5 or 5' in
the
following manner: in another preferred embodiment of the present invention as
shown
in Figs. 9 and 10, the vertical extent of slot 5 is substantially increased
upwardly or
downwardly from the embodiment shown in Figs 1 and 2. This° might be
thought of a
"super-slot". Preferably, this is accomplished by extending the cut out
portion 9 in a
substantially upwaxd direction, although extending cut out portion 9 downwards
into
basket body 10 may also be performed. When formed in the lid, this extension
will
often exceed one half of the lid portion of basket 1. Vent slot 5' may be
formed by a
substantially similar cut out portion 9' formed at the front of lid and a
corresponding
aperture, 14', formed in hinge 12. Aperture 14' is shown having reference to
Fig. 3.
3o Yet another cooling regime may be implemented in accordance with the
teachings of the present invention. In this case the previously discussed
cooling
channel, 13, is eliminated. An end view of a basket constructed according to
this
embodiment of the present invention in shown having reference Fig.2A.
Comparison
of Figs. 2 and 2A illustrates the elimination of channel 13. Lower vent
apertures, not
12
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
shown in this figure, may be implemented in a lower surface of basket 1. One
means
of implementing these lower vent apertures is by means of vent bosses formed
either
upwardly or downwardly from a lower surface of basket 1.
While the previously discussed latch configuration has been shown to be
particularly effective, the principles of the present invention specifically
contemplate
alternative latching methodologies. These include, but are specifically not
limited to,
edge catches, button catches, snaps, hook-and-loop closures, and other closure
methodologies well-known to those having ordinary skill in the art. Moreover,
the
term "latch" as used herein may further comprise alternative lid closure
1o methodologies known to those having ordinary skill in the art including
shrinkwrap
banding the lid to the body, and the use of elastic bands or adhesive tapes to
perform
this latching function. One basket formed utilizing such an alternative
closure
methodology is shown having reference to Fig. 3A.
In accordance with this aspect of the present invention, the previously
discussed
latch pairs 16 and 17 are replaced with at least one and preferably a
plurality of button
detent pairs 51 and 53. Well-known to those having ordinary skill in the art,
button
detents consist of a mating male and female latch pair, for instance 51 and
53, which
secure the package by inserting the male member into the female member. The
elastic deformation of at least one of the male and female members results in
securing
the closure of the package. Fig. 3A discloses a number of alternative
embodiments of
the present invention including the use of the previously discussed button
detents 51
and 53. The button detents 51 and 53 may be advantageously defined on lips 14
and
15. One means of so forming these detents on lips 14 and 15 is by means of a
button
detent boss, generally 55.
Fig. 3A further discloses an alternative to the single aperture 14' shown in
Fig.
3. According to this aspect of the present invention, single aperture 14' may
be
replaced by a plurality of smaller apertures 57 defined across the vertical
aspect of
hinge 12. The present invention specifically contemplates a number of
geometries for
both aperture 14' and apertures 57. These include but are specifically not
limited to,
3o circles, oblongs, squares, rectangles, polygons, and figures. Examples of
the latter
may include letters, numerals, and geometric or cartoon shapes.
Also shown in Fig. 3A is the use of a median catch for precluding lateral
motion between basket body 10 and lid 11. It has been found that when large
baskets
are handled, for instance the large baskets used for multiple-pound industrial
packs of
13
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
strawberries, it is often advantageous to provide a methodology for precluding
the
lateral movement of lid 11 with respect to basket body 10. One methodology of
precluding this unwanted movement is the placement of a button catch, for
instance
the button catch defined by pairs 59 and 61, at some point between latch pairs
51 and
53 were 16 and 17. In order to provide the requisite compression strength to
enable
securing this median button catch 61/59, one or both of button catch members
59 and
61 may be advantageously mounted on a pilaster formed in one or both of basket
body 10 and basket lid 11.
Having reference now to Figs. 4 and 5 a first preferred tray, 2, formed
to according to the principles of the present invention is shown. Tray 2 is
sized to hold
at least one and preferably a plurality of baskets (not shown in this figure).
In one
preferred embodiment of the present invention, tray 2 holds six baskets 1. A
particular feature of tray 2 is the plurality of tray vents 25 and 25'. As
shown in Fig.
5, tray vents 25 and 25'align with the previously discussed vent channels
formed in
the bottom of baskets 1. In this manner, a direct path is created from the
ambient
atmosphere to the bottom surface of each basket 1 loaded into tray 2. Trays 2
are
formed such that when stacked a lateral vent slot 26 is formed between each
pair of
trays 2. Air vented from baskets 1 is vented from tray 2 at vent slots 27.
This means
of tray ventilation, together with the previously described improvements in
baslcet
2o ventilation combine to ensure that all berries in the tray receive
significantly greater
cooling ventilation than any previous fruit cooling and packaging system,
thereby
creating significant reductions in cooling energy requirements. Indeed,
preliminary
testing indicates that the improved cooling afforded by the ventilation
arrangement of
the present invention may cut cooling costs for some strawberry packing
operations
by as much as 25%.
With continued reference to Fig. 4, tray 2 is further formed with at least one
cutaway section, 35, which aligns with the horizontal ventilation slot of
baslcet 1,
when loaded into tray 2. This provides for improved flow of cooling air
towards the
top of basket 1 when loaded in tray 2. A second cutaway section, 35" is formed
on
3o the ends of tray 2 to enable the bi-directional flow of cooling air
previously discussed.
A second plurality of tray vents 25" is also formed in the ends of tray 2.
Where
adjacent ones of tray 2 are loaded perpendicularly, for instance on a pallet,
vet slot 26
of one tray aligns with one or more cutaway portions 35 or 35' on the adjacent
tray to
14
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
enable the cooling flows previously described across trays which are so
positioned
perpendicular to one another.
Having reference now to Figs. 1 l and 12, cutaway section 35 may be formed
into a further plurality of sections 35', separated by divider tabs 50.
Sections 35'
serve to direct the flow of cooling air only into horizontal slot 5 of basket
1 (not
shown in this figure). In tlus manner, cooling efficiency is improved. The
flow of
cooling and vent air provided by this embodiment is shown in Fig 12.
With continued reference to Fig. 4, trays 2 are formed to minimize lateral
movement of one tray with respect to another by means of at least one tab 28
formed
to at an upper edge of tray 2 in operative combination with at least one
receptacle 29
similarly formed on a substantially lower edge of the corresponding side. In
this
manner, when a plurality of trays 2 are loaded, for instance onto a pallet,
tab 28 of a
lower tray is received into receptacle 29 of the tray loaded onto it. Tab 28
may be
formed to accept therein stacking wires (not shown in this figure), in
accordance with
generally accepted container design practice. These staclcing wires generally
take the
form of an elongated U-shaped member which are inserted through tab 28 of one
tray
and thence through corresponding tabs 28 of one or more trays stacked thereon.
Stacking wires thus utilized not only reduce lateral movement of one tray with
respect
to another, but can also form a handle for the facile handling of a plurality
of trays at
one time.
Having reference now to Fig. 8, a significant savings in shipping costs is
realized by sizing baskets l and trays 2 as a system to maximize the area or
shipping
footprint of a layer of trays on a pallet. As previously discussed, the 40
inch by 48
inch pallet is the preferred standard size in the grocery business in the
United States.
Current Michigan baskets measure approximately 43/4" by 71/4" by 31/2" tall
when
closed and are loaded eight per tray.. This tray measures approximately 193/
inches
by 153/4 inches. A maximum of six such trays constitute a layer on a 40 inch
by 48
inch pallet. Where the trays are loaded with one pound strawberry baskets, a
maximum of 48 pounds of fruit may thus be loaded in each layer. In contrast,
baskets
of the present invention designed to receive therein one pound of strawberries
are
sized approximately 6 3/8" x 5" x 33/4 high, when closed. Tray 2 of the
present
invention is sized at approximately 16" x 131/4". This size maximizes the
footprint on
a standard pallet. This means that nine such trays can be loaded as a layer on
the
previously described pallet, for a total of 54 pounds of fruit per layer. This
represents
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
an increase of 6 pounds, or 16 percent per layer over the Michigan basket.
Since the
shipper is not paying for wasted shipping volume his shipping costs are
reduced,
which can result in further savings to the consumer. Moreover, the sizing of
baskets
and trays may be optimized to effect the "5-down" stacking shown in Fig. 8.
The vertical mating surface of the Michigan trays, that portion of the baskets
which abut one another when loaded into trays, comprises little more than the
mated
edges of two thin sheets of plastic. Accordingly, because those mating
surfaces
protrude, and due to the thin nature of their vertical aspect, the mating
surfaces of the
Michigan basket are very much prone to over-riding one another. This allows
the
to baskets to shift markedly inside the tray, which is a significant factor in
the bruising
of fruit stored in the baskets. Referring again to Fig. 2, it will be
appreciated that to
overcome this limitation, the baskets of the present invention further
comprise an
edge mating surface 30 formed by hinge 12 and latches 17. This edge mating
surface
is relatively broad in comparison to the Michigan baskets described herein.
The
combination of this relatively broad mating surface with a properly sized
baslcet/tray
combination has been shown to be especially effective in the reduction of
damage to
fruit stored therein.
The preceding discussion of a first preferred embodiment of the present
invention has focused on one specific berry package design. It will be
immediately
obvious to those of ordinary skill in the art that the principles set forth
herein are also
applicable to a wide range of produce package sizes and utilizations. By way
of
illustration but not limitation, the present invention specifically
contemplates the
forming of 1 pint and 1/2 pint (also referred to 8 oz. or 250 g.) berry
baskets, as well
as baskets configured to receive therein specific produce shapes, types and
counts.
An example of the latter is the "long stem pack" used in the berry industry
for
shipping specific package counts of large, premium berries. Furthermore, while
the
discussion of the principles set forth herein has centered on packages for the
berry
industry, it is recognized that these principles may be applied with equal
facility to the
packaging of a broad range of materials including other foodstuffs or any item
which
3o would benefit from the advantages set forth herein. Such applications are
specifically
contemplated. These principles include the use of a family of trays, having
fixed
"footprints" or lengths and widths, but with whose heights are varied to
accommodate
baskets having different heights and/or counts per tray. By maintaining the
footprint
at a constant value, the advantages of miumizing lateral movement between
16
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
individual trays and between layers of trays are attained because the trays of
one layer
interlock with the layer of trays above or below it. This is true even where
adjacent
tray layers contain significantly differing sizes of baskets, holding the same
or
different produce items.
Where the tray is designed to receive one pound strawberry baskets as
previously discussed, the height of the tray is approximately 3-3/4 inches.
Where
other berries, or indeed other produce products are shipped, the length and
width of
the tray do not change, but remain at the previously defined optimal size.
Changes in
tray volume necessary to accommodate differing numbers and volumes of baskets
are
1o accommodated by altering the height of the tray. In similar fashion,
baskets designed
for use in the present system are sized to fit within the previously discussed
tray. In
this manner, baskets suitable for substantially any size basket designed for
consumer
use, as well as many baskets sized for the food service industry, may be
accommodated by the present invention. This presents the previously described
15 advantage of enabling the shipment of a mixed pallet of differing produce
by loading
trays optimized for each type of produce onto separate, compatible layers.
Moreover, tray 2 may be formed to receive therein a plurality of layers of
filled baskets 1. Examples of such embodiments are shown in Figs. 15-18 Having
reference now to Figs. 17 and 18, one embodiment of the present invention
designed
2o to hold two layers of the filled baskets is shown. In this embodiment, the
first
described cooling air regime is selected, and both tray vents 25 and
horizontal
cutaway sections 35' are employed. Moreover, at least one pair of modified
tray
vents, 25' is formed on opposite sides of tray 2 to perform the functions of
tray vent
25 for the upper layer of baskets l, and cutaway sections 35' for the lower
layer of
25 baskets 1. Modified tray vents 25' may be formed with a number of
geometries. Two
such are shown in Figs. 17 and 18.
With continued reference to Fig. 4, tray 2 in a first preferred embodiment is
formed of cut and folded corrugated cardboard formed in a manner well known to
those of skill in the art. One such corrugated cardboard is Georgia-Pacific
USP120-
30 33sm1-USP120, although any number of packaging materials well knovm to
those of
ordinary skill in the art could, with equal facility, be used. Such
alternative materials
include, but are not limited to various cardboards, pressboards, flakeboards,
fiberboards, plastics, metals and metal foils. In some embodiments of tray 2,
it may
further be advantageous to incorporate a gluing, adhesive or fastening step in
17
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
fabrication of the tray, again in accordance with generally accepted practices
in
container design and fabrication.
Because of the smaller size of the trays of the present invention, a lighter
grade of corrugated board is may be used for their manufacture than are trays
required
to support the greater weight and greater area of the Michigan baskets
previously
described. This lighter weight not only minimizes shipping costs, but can
significantly reduce packaging costs for the shipper, again lowering consumer
costs.
While the tray of a first preferred embodiment is formed of corrugated
cardboard, the
principles of the present invention may with equal facility be implemented on
a
l0 variety of alternative tray materials. Such alternative materials include,
but are not
limited to various polymeric and monomeric plastics again including but not
limited
to styrenes, polyethylenes including HDPE and LPDE, polyesters and
polyurethanes;
metals and foils thereof; paper products including chipboard, pressboard, and
flakeboard; wood; wire; and combinations of the foregoing.
15 Another preferred embodiment of the present invention, implementing an
alternative cooling air regime, can be provided by altering the ventilation
provided by
tray 2. In this general class of embodiments, shown in Figs. 13-16, tray vents
25 or
25' of the previously discussed embodiments are eliminated, and substantially
all
cooling air is directed to horizontal slots 5 of baskets 1 through cutaway
sections 35
20 or 35' of tray 2. An example of such a tray, formed to receive therein a
single layer of
baskets l, is shown in Figs. 13 and 14. Another such tray, formed to receive
therein a
plurality of layers of baskets 1 is shown in Figs. 15 and 16. Each of trays 2
shown in
Figs. 13-16 are shown as employing divider tabs 50. In studying the principles
of the
present invention, those having ordinary skill in the art will note that this
second
25 cooling air regime may, with equal facility, be implemented without
recourse to
divider tabs 50.
Each of the embodiments shown in Figs. 1-18 enables the flow of cooling air
from any side of the tray and basket, with a corresponding outflow of vent
from the
opposite side of the tray and basket. This in turn enables the positioning of
trays,
3o within a given layer, in either perpendicular or parallel orientations with
respect to
one another, as shown at "X" and "Y" in Fig. 8. This finally enables the
previously
discussed "5-down" and "10-down" arrangement of trays, currently deemed
desirable
by the produce and packaging industries.
18
CA 02458695 2004-03-10
WO 03/022685 PCT/US02/28338
The present invention has been particularly shown and described with respect
to certain preferred embodiments and features thereof. However, it should be
readily
apparent to those of ordinary skill in the art that various changes and
modifications in
form and detail may be made without departing from the spirit and scope of the
inventions as set forth in the appended claims. In particular, the use of
alternative
basket forming technologies, tray forming technologies, basket and tray
materials and
specifications, basket shapes and sizes to conform to differing produce
requirements,
and vent configurations axe all contemplated by the principles of the present
invention.
to
19
