U.S. patent application number 10/760608 was filed with the patent office on 2005-07-21 for modular and stackable tray assembly.
Invention is credited to Lown, John M..
Application Number | 20050155889 10/760608 |
Document ID | / |
Family ID | 34750029 |
Filed Date | 2005-07-21 |
United States Patent
Application |
20050155889 |
Kind Code |
A1 |
Lown, John M. |
July 21, 2005 |
Modular and stackable tray assembly
Abstract
A system of open top trays of variable heights arranged to be
stacked in any arrangement and with the trays in a stacked position
defining a common interface datum plane between adjacent trays and
releasably locked together. Each tray includes a bottom,
longitudinal and transverse perimeter walls, with the perimeter
walls being inclined outwardly and terminating in an upper rim,
with the perimeter of each tray having the same dimensions
regardless of its height. A latch handle is rotatably mounted on
each transverse wall at a distance d.sub.1 below the datum plane. A
latch hook protrudes outwardly from each transverse wall at a
distance d.sub.2 above the datum plane with the latch handle having
a locking tab for engaging an associated latch hook of an above
positioned tray to releasably lock the trays together.
Inventors: |
Lown, John M.; (Huntington
Beach, CA) |
Correspondence
Address: |
Harold L. Jackson, Jackson Law Corporation
14751 Plaza Dr., Ste. N
Tustin
CA
92780
US
|
Family ID: |
34750029 |
Appl. No.: |
10/760608 |
Filed: |
January 20, 2004 |
Current U.S.
Class: |
206/501 |
Current CPC
Class: |
A01K 97/06 20130101;
B25H 3/021 20130101 |
Class at
Publication: |
206/501 |
International
Class: |
B65D 006/28 |
Claims
What is claimed is:
1. A system of open top trays of variable heights arranged to be
stacked and releasably locked together in any arrangement
independent of the individual tray heights, the trays in a stacked
position defining a common interface datum plane between adjacent
trays, each tray comprising: a bottom and longitudinal and
transverse perimeter walls terminating in an upper rim defining an
opening through which articles may be placed in and removed from
the tray, the perimeter walls being inclined outwardly with respect
to the vertical with the rim of each tray having the same
dimensions regardless of the height of the tray; an axle spaced
outwardly from each transverse wall to accommodate a rotatable
latch handle mounted thereon, the axle being located below the
datum plane by a first predetermined distance d.sub.1; a latch hook
protruding outwardly from each transverse wall and located above
the datum line a second predetermined distance d.sub.2; and a latch
handle rotatably mounted on each axle, the latch handle having a
locking tab arranged to engage the associated latch hook of an
above positioned tray when the latch handle is rotated to a closed
position.
2. The system of claim 1 wherein the peripheral walls include an
inwardly stepped section joined to the bottom with the stepped
section providing a mating interface with the upper edge of the
peripheral walls of a below positioned tray and defining the datum
plane so that when the trays are in a stacked relationship the
peripheral walls of each container are substantially aligned.
3. The system of claim 2 wherein the transverse walls have a
recessed center section and wherein the axles and latch hooks are
positioned in the center sections.
4. The system of claim 2 wherein each latch handle terminates at
one end in the shape of an inverted j-hook defining a groove
arranged to fit over the associated axle and terminates at the
other end in a finger engaging surface with any intermediate
inwardly extending locking tab, the j-hook portion defining a
convenient handle for carrying one or several stacked trays.
5. The system of claim 4 wherein the longitudinal peripheral walls
of the tray define a plurality of vertically oriented opposing
divider receiving guides.
6. The system of claim 5 wherein each guide is formed by a pair of
elongated opposed generally semicylindrical sections defining a
narrow slot therebetween.
7. The system of claim 2 wherein the distance d.sub.3 between the
axles and the distance d.sub.4 between the latch hooks are the same
regardless of the height of the tray.
8. The system of claim 2 further including a cover having
longitudinal and transverse perimeter sections with the transverse
sections having a recessed center portion with a protruding latch
hook on each transverse center portion section, the perimeter
sections defining an overcut portion adjacent the bottom thereof
with a horizontally oriented shelf arranged to engage the rim of an
underlying tray, the latch hook being positioned above the shelf by
the distance d.sub.2.
9. The system of claim 8 wherein the perimeter sections of the
cover further define an overhanging vertically oriented skirt
arranged to extend over the outside of the upper portion of the
perimeter walls of an underlying tray.
10. The system of claim 9 wherein a rotatable handle is mounted on
the top of the cover.
11. An assembly of compartmentalized trays of variable heights
arranged to be stacked and releasably locked together, each tray
comprising: a bottom and longitudinal perimeter walls and
transverse perimeter walls with the perimeter walls being inclined
outwardly at angle .theta. and terminating in an upper rim defining
an opening through which articles may be placed in and removed from
the tray, each transverse wall having a central section; a
plurality of dividers mounted in the tray to form individual
compartments; an axle positioned adjacent the upper edge and spaced
from the central section of each transverse wall to accommodate a
rotatable latch handle mounted thereon; a latch hook protruding
outwardly from each transverse wall adjacent the bottom in vertical
alignment with the axle; and a latch handle rotatably mounted on
each axle, the latch handle having a locking tab arranged to engage
the associated latch hook of an above positioned tray when the
handle is rotated to a latched position.
12. The container assembly of claim 11 wherein .theta. is within
the range of about 0.5.degree. to 2.degree..
13. The container assembly of claim 12 wherein the peripheral walls
include an inwardly stepped section joined to the bottom with the
stepped section accommodating the rim of another container so that
when the containers are in a stacked relationship the peripheral
walls of each container are substantially aligned.
14. The container assembly of claim 13 wherein each latch handle
defines a groove at one end which fits over the associated axle, a
finger engaging surface at the other end and an intermediate
locking tab.
15. The container assembly of claim 14 wherein each transverse
perimeter wall is formed with an inwardly stepped center section
with the axle extending across the center section adjacent the
upper edge and an outwardly extending latch hook disposed in the
center section adjacent the bottom.
16. A system of open top trays of variable height arranged to be
stacked and releasably locked together in any arrangement
independent of the individual tray heights, the trays in a stacked
position defining a common interface datum plane between adjacent
trays, each tray comprising: a bottom and longitudinal and
transverse perimeter walls terminating in an upper rim defining an
opening through which articles may be placed in and removed from
the tray, the perimeter walls being inclined outwardly with respect
to the vertical with the rim of each tray having the same
dimensions regardless of the height of the tray; a latch handle
rotatably mounted on each transverse perimeter wall about an axis
located below the datum plane by a first predetermined distance
d.sub.1; and a latch hook protruding outwardly from each transverse
wall and located above the datum line a second predetermined
distance d.sub.2, the latch handle having a locking tab arranged to
engage an associated latch hook of an above positioned tray when
the latch handle is rotated to a closed position.
17. The invention of claim 16 wherein the latch handle is formed
with a central section and a stub axle extending outwardly from the
central section along the axis of rotation and wherein the
transverse perimeter walls define opposed openings for receiving
the stub axles.
18. The invention of claim 17 wherein the transverse perimeter
walls include a recessed center section located between
perpendicularly extending side walls, the side walls defining the
openings for the latch handle stub axles.
19. The system of claim 18 wherein the peripheral walls include an
inwardly stepped section joined to the bottom with the stepped
section providing a mating interface with the upper edge of the
peripheral walls of a below positioned tray and defining the datum
plane so that when the trays are in a stacked relationship the
peripheral walls of each container are substantially aligned.
20. The system of claim 19 wherein the longitudinal peripheral
walls of the tray define a plurality of vertically oriented
opposing divider receiving guides.
21. The system of claim 20 further including a cover having
longitudinal and transverse perimeter sections with the transverse
sections having a recessed center portion with a protruding latch
hook on each transverse center portion section, the perimeter
sections defining an overcut portion adjacent the bottom thereof
with a horizontally oriented shelf arranged to engage the rim of an
underlying tray, the latch hook being positioned above the shelf by
the distance d.sub.2.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an assembly of individual
trays of different heights which can be releasably locked together
and carried as a single unit.
[0003] 2. Description of the Prior Art
[0004] Boxes, and particularly compartmentalized boxes, for storing
craft, fishing hardware and other small items (e.g., beads, lures,
screw, etc.) are generally configured as single units with lids.
Each unit is generally carried separately or stacked in an
unsecured arrangement. Picking up and transporting a pile of such
boxes can easily cause an unexpected separation of the piled boxes
spilling the contents thereof.
[0005] Stackable storage containers which can be releasably locked
together are known as illustrated, for example, in U.S. Pat. No.
3,339,725 ("'725 patent"); U.S. Pat. No. 4,619,363 ("'363 patent");
and U.S. Pat. No. 6,273,258 ("'258 patent").
[0006] The '725 patent employs a flat sheet (1) of cardboard or the
like with the central section extending over the top container and
the end sections extending along the sides of the single or stacked
container(s) and secured to the beaded rim(s) surrounding the
openings(s) of the lower container(s). The sheet (1), which holds
the containers together, constitutes an extra component and does
not provide a particularly reliable/reusable locking system.
[0007] The '363 patent discloses a storage unit in which two trays
of different heights and apparently vertically aligned side walls
may be stacked and carried as a unit. A separate connecting element
(13) is releasably secured between the sides of each pair of
stacked trays. While the connecting elements would apparently
provide a secure locking arrangement between the several trays,
they would be cumbersome to use. The patent refers to the possible
use of a hinged connecting element, as an alternative. However, no
specifics are given as to its construction.
[0008] The '258 patent discloses a stackable container system for
storing foodstuffs in which identical containers are secured
together by flexible flaps (18). Such a flexible flap arrangement
is not particularly robust. Also, absent the presence of the lid
22, there is no convenient handle with which to carry the stacked
containers.
[0009] There is a need for a economical and stackable tray assembly
with a robust locking mechanism, particularly for a stackable tray
system in which the trays have different heights with optional
dividers to form individual compartments within the trays. For
economic reasons trays and other containers for storing small items
are often injection molded of a plastic material such as
polypropylene, polyethylene or copolymers. A split two-part mold
can be employed to form straight peripheral or side walls in such
trays. While the use of a single non-split mold will result in a
simpler and less expensive molding process, the peripheral walls
must be outwardly inclined (i.e., draft angle) in order to remove
the molded tray from the mold. The releasable locking arrangement
of my invention accommodates stacked trays of different heights and
the use of a single mold for each tray height.
SUMMARY OF THE INVENTION
[0010] A system for open top trays of variable heights arranged to
be stacked together in any arrangement, in accordance with the
present invention, comprises a group of trays with each tray having
a bottom and longitudinal and perimeter walls which terminate in an
upper edge or rim defining an opening through which articles may be
placed in and removed from the tray. Preferably a plurality of
dividers are mounted in the tray to form individual compartments.
The peripheral walls have an inwardly stepped or undercut section
joined to the bottom which undercut section nests on the rim of the
lower tray in a complementary manner to substantially align the
peripheral walls of the nested trays with the rim of each tray
having the same dimensions regardless of the tray height. The trays
in a stacked position define a common interface datum plane
coincident with the rim of the lower tray. A latch handle is
rotatably mounted on the exterior of each transverse perimeter wall
about a rotational axis located at a distance d.sub.1 below the
datum plane and a latch hook protrudes outwardly from each
transverse wall at a distance d.sub.2 above the datum plane. The
latch handle includes a locking tab arranged to engage the latch
hook of an above positioned tray (or lid) when the latch handle is
rotated to a closed position.
[0011] Preferably each latch handle is rotatably mounted on an axle
molded integrally with the transverse walls and spaced outwardly
from a recessed central section thereof Alternatively the latch
handles may be provided stub axles positioned in an axle receiving
openings in the transverse walls adjacent a recessed central
section thereof.
[0012] Preferably the rotational axis of the latch handles and the
latch hooks are separated by distances d.sub.3 and d.sub.4,
respectively, regardless of the height of the tray. The underside
of the latch handle (in the locked position) has a generally
semicylindrical shape to provide a user friendly handle portion for
lifting and transporting stacked trays. Preferably the trays are
provided with integrally molded or removable dividers to form
compartments within the individual trays.
[0013] In addition the assembly includes a lid with a top wall,
longitudinal and transverse side walls with a latch hook extending
outwardly from each transverse wall and above the datum plane by
the distance d.sub.2 for engagement by the locking tab of an
associated latch handle on the underlying tray. The lid further
includes a pivotal handle in the center section of the lid top wall
to accommodate the hand of a user desiring to lift and transport
the stacked assembly.
[0014] The modular and stackable tray assembly of the present
invention may best be understood in reference to the following
description taken in conjunction with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a stackable tray assembly
including a cover or lid in the stacked and locked position in
accordance with the present invention.
[0016] FIG. 2 is a side elevational view of the assembled trays of
FIG. 1.
[0017] FIG. 3 is a front elevational view of the assembled trays of
FIG. 1.
[0018] FIG. 4 is an exploded disassembled perspective view of the
trays of FIG. 1.
[0019] FIGS. 5 and 6 are perspective views of the lower and
assembled lower and intermediate trays shown in FIG. 1,
respectively.
[0020] FIG. 7 is a cross sectional view, partially broken away,
taken along lines 7-7, of FIG. 2, showing the releasable locking
arrangement for the individual trays with the dividers illustrated
in FIG. 4 not shown for clarity.
[0021] FIG. 8 is an enlarged view of the releasable locking
arrangement between two of the trays of FIG. 7 illustrating various
dimensions.
[0022] FIG. 9 is an enlarged view of the releasable locking
arrangement between the cover or lid and one of the trays of FIG. 7
illustrating various dimensions.
[0023] FIGS. 10 and 11 are perspective views of the front and rear
sides of the latch handle, respectively.
[0024] FIGS. 12 and 13 are top and bottom plan views of the cover
or lid, respectively.
[0025] FIG. 14 is a perspective view of the handle for the
cover.
[0026] FIG. 15 is a perspective view of an alternative latch
handle.
[0027] FIG. 16 is a partial perspective view of a transverse
peripheral wall of a tray showing an opening therein for receiving
the stub axles of the alternative latch handle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] Referring now to FIGS. 1-5 a tray system or assembly
designated generally at 10 of the present invention includes a
plurality of open top trays with a bottom tray 12, an intermediate
tray 14, an uppermost tray 16 and a cover or lid 18.
[0029] The trays are injection molded, preferably with a one piece
mold, of a suitable rigid thermoplastic material such as
polypropylene, polyethylene or a copolymer. Preferably, the trays,
i.e., at least two, have different heights, h. As an example, a set
of four trays may have heights of 4", 3", 2" and 11/4" and have
suitable lengths and widths such as 16" and 8", respectively. It is
to be understood that the specific dimensions given are by way of
example only.
[0030] As is illustrated more particularly in FIGS. 5 and 7, each
tray includes a bottom wall 20, longitudinal peripheral walls 22,
and transverse peripheral walls 24 (collectively "peripheral
walls") with the peripheral walls being inclined outwardly to the
vertical (at an angle designated as .theta. in FIG. 3) to
accommodate removal from the mold. The peripheral walls terminate
in a an upper edge or rim 25 through which articles may be placed
in and removed from the open trays. The angle .theta. of the
inclination may be in the range of 0.5.degree. to 2.degree. with
the angle dependent upon the height h of the tray so that the rim
of the trays have substantially the same dimensions for nesting
purposes as will be explained. The peripheral walls are joined to
the bottom via an inwardly stepped or undercut section 23 (FIG. 7)
which mates with the rim of the lower tray to align the peripheral
walls and maintain the trays in a nested arrangement. As is
illustrated in FIG. 8 a horizontally oriented shelf 23a of the
undercut section rests on the rim 25 of the lower tray.
[0031] The longitudinal and transverse peripheral walls are joined
at a radiused corner sections 26 (FIG. 5) with the center sections
22a of the longitudinal walls recessed slightly, as illustrated,
for decorative purposes. A central section 24a of the transverse
walls is also recessed with axle 28 integrally molded into the side
sections 24b and spaced outwardly from the central section (FIG. 1)
to accommodate an axle receiving groove 30a in a latch handle 30
(FIG. 14) rotatably mounted on the axle as will be explained in
more detail (the side sections 24b extending perpendicularly
outwardly from the central section 24a). The center of the axle is
supported via a stub support member 28a which extends outwardly
from the recessed center portion 24a. See FIG. 8. The peripheral
walls include circumscribing outwardly protruding ribs 3 1,
adjacent the rim, for decorative purposes. See FIG. 5.
[0032] A protruding latch hook member 32 (extending upwardly from
two spaced horizontal ribs 32a) is also integrally molded in the
bottom of the center section 24a of each transverse peripheral wall
for receiving a locking tab 30b on the latch handle when in its
closed position to lock the several trays together. See FIGS. 1, 8
and 9. The latch handle is formed with a tab 30c which may be
rotated by a user's finger to engage or disengage the locking tab
from the latch hook 32 to lock or unlock the trays. The underside
30d of the bottom of the latch handle is semicircular in shape and
serves as a handle for lifting one or a stack of trays. The center
section of the bottom of the latch handle is notched at 30e to
accommodate the stub support member 28a. See FIGS. 10 and 11.
[0033] As discussed earlier the trays, in a stacked position, with
the undercut shelf 23 a of the upper shelf resting on the rim 25 of
the lower shelf, define a datum plane coincident with the lower
tray rim as is illustrated in FIG. 8.
[0034] The axle 28 is spaced below the datum plane by a distance
d.sub.1 with the latch hook 32 spaced above the datum plane by a
distance d.sub.2 in each tray regardless of the tray height. The
distance between the center of the latch handle groove 30a and the
locking tab equals d.sub.1+d.sub.2. Preferably the distances
d.sub.3 and d.sub.4 between the axles 28 and latch hooks 32,
respectively, on each tray, regardless of tray height, are the same
so that the axles and latch hooks will be aligned vertically
(although in different planes as illustrated) with the trays in a
stacked position as is illustrated in FIG. 7.
[0035] Referring now to FIGS. 1, 12 and 13 the cover or lid 18
includes longitudinal and transverse perimeter walls 18a and 18b,
respectively, with a center section 18c of each transverse wall
being recessed for alignment with the recessed center sections 24a
of the trays in the stacked position. The sections 18c are molded
with protruding latch hooks 32', aligned with the latch hooks 32,
of the lower stacked trays. As is illustrated in FIG. 9 the locking
tab 30b of the lower tray latch handle engages the latch hook 32'
to lock the cover to the underlying tray(s). As is illustrated in
FIG. 9, the distances d.sub.5 and d.sub.6 represent the distances
between the axles 28 and latch hooks 30b, respectively, from the
recessed wall sections 28a.
[0036] The lower end of the cover perimeter sections are formed
with an overcut section 18d defining a horizontally extending shelf
18e and an overhanging vertically oriented skirt 18f. The shelf 18e
rests on the rim of the underlying tray and defines the datum plane
for determining the distance d.sub.2 as is best illustrated in FIG.
9. The skirt 18f fits over the outside of the rim and upper portion
of the perimeter walls of the lower tray.
[0037] The upper side of the cover includes a depressed center
section 18g, merged between side sections 18h via vertically
oriented stub walls 18i. The stub walls have openings 18j for
receiving stub axles 36a of a handle 36. See FIGS. 1 and 14. The
longitudinal and peripheral sections of the cover include
decorative curved sections 18k merged with the overcut section
18d.
[0038] As is best illustrated in FIG. 13 the underside of the
center section of the cover is designated 18g. Strengthening ribs
18l are also included on the underside of the cover.
[0039] Referring now to FIGS. 4 and 5 divider receiving guides 38
are integrally molded to the interior surfaces of the longitudinal
perimeter walls of trays 12 and 14 with removable dividers 40
mounted in some of the guides. Each guide is formed by a pair of
elongated opposed generally semicylindrical sections 38a defining a
narrow slot therebetween for receiving and releasably retaining a
divider 40. Preferably the removable dividers are formed with
semicylindrical end sections 40a which are complementary with the
elongated cavities formed by the sections 38a. See FIG. 5.
[0040] One or more dividers 42 may be integrally molded with the
trays as illustrated in tray 16 of FIG. 4. In addition vertically
oriented spool receiving posts 42 may be integrally molded in a
section of a tray. Alternatively, the posts 42 may be molded to a
removable plate (not shown) for placement in a section of the tray
as in FIG. 4.
[0041] The dividers may have a height, such as is illustrated in
the tray 14, so that the bottom of a overlying tray will be
positioned closely above the dividers to inhibit any articles from
spilling from one compartment to another in the event that the
locked assembly is tipped upside down.
[0042] As an alternative to the latch handle and fixed axle
arrangement shown in FIGS. 1 and 9-11, the latch handle (designated
40) may be in the form shown in FIG. 15 and 16 with stub axles
extending into openings 42 in the transverse wall side sections
24b'. With either arrangement the latch handle rotates about an
axis of rotation located at distance d.sub.1 below the datum
plane.
[0043] While the trays and cover may be molded of any suitable
plastic, they are preferably made of polypropylene. I have found
that the nominal wall thickness t of 0.080" for the trays is
suitable while a somewhat greater thickness may be preferable for
the skirt sections of the top since the top must carry the weight
of the stacked assembly when the handle 36 is used to transport the
underlying trays. It is to be noted that the semicylindrical latch
handle portions 30d may be used to carry the assembled trays with
or without the cover in place.
[0044] There has thus been described a novel modular and stackable
tray assembly with the individual tray arranged to accommodate
removable or stationary dividers to form compartments and a
reliable locking system to allow a stacked tray assembly to be
conveniently carried with or without a cover. Various modifications
to the invention will become apparent to those skilled in the art
without involving any departure from the spirit and scope of the
present invention as defined in the appended claims.
* * * * *