U.S. patent application number 11/098060 was filed with the patent office on 2005-10-27 for nestable and stackable document storage trays.
Invention is credited to Cavada, Gilberto JR., Conklin, Melanie L., Killinger, Timothy D., Lerch, Matthew G., Smith, Aaron W..
Application Number | 20050236348 11/098060 |
Document ID | / |
Family ID | 34964784 |
Filed Date | 2005-10-27 |
United States Patent
Application |
20050236348 |
Kind Code |
A1 |
Killinger, Timothy D. ; et
al. |
October 27, 2005 |
Nestable and stackable document storage trays
Abstract
Document storage trays are disclosed that may be stacked in at
least two different configurations including a "nesting" stack
where an upper tray fits within the storage area of a lower tray
and, in turn, is also able to receive a tray within its own storage
area so that multiple trays can be stacked nested together. The
document storage trays may also be stacked in a vertical
configuration and the trays include appropriately placed slots,
detents, bosses and legs for a stable vertical stacking
configuration so that multiple trays may be stacked one on top of
another and form a stable structure. At least one embodiment
further enables the trays to be stacked in a cascaded form so that
front edges of the trays are staggered laterally from the bottom
tray to the top tray. At least one embodiment includes a built-in
collating function so that each tray is able to receive documents
from one of two different and perpendicularly oriented sides.
Inventors: |
Killinger, Timothy D.;
(Plainfield, IL) ; Lerch, Matthew G.; (Chicago,
IL) ; Smith, Aaron W.; (Plainfield, IL) ;
Cavada, Gilberto JR.; (Melrose Park, IL) ; Conklin,
Melanie L.; (Chicago, IL) |
Correspondence
Address: |
MARSHALL, GERSTEIN & BORUN LLP
233 S. WACKER DRIVE, SUITE 6300
SEARS TOWER
CHICAGO
IL
60606
US
|
Family ID: |
34964784 |
Appl. No.: |
11/098060 |
Filed: |
April 4, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60559312 |
Apr 2, 2004 |
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60592366 |
Jul 29, 2004 |
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60590146 |
Jul 22, 2004 |
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Current U.S.
Class: |
211/126.7 |
Current CPC
Class: |
B42F 7/12 20130101 |
Class at
Publication: |
211/126.7 |
International
Class: |
A47F 003/14 |
Claims
What is claimed is:
1. A document tray comprising: a bottom panel having a rear edge, a
forward edge, a pair of opposed side edges and an upper and lower
surface; a rear wall extending upward near the back edge of the
base panel and having a lower edge, an upper edge, and a pair of
side edges; a pair of side walls spaced apart and opposed relative
to one another, one each extending generally upward relative to a
respective one of the side edges of the bottom panel; a storage
space defined above the bottom panel, forward of the rear wall, and
between the side Walls; a rim which extends laterally outward from
top edges of the side walls and rearwardly from the upper edge of
the back wall forming a lip on the top edges of the side walls and
the upper edge of the rear wall; a pair of lateral extensions, one
each formed near the forward edge of the bottom panel extending
laterally outward beyond the side edges of the bottom panel and
protruding outward beyond an exterior perimeter of the rim.
2. The document tray of claim 1, wherein the bottom panel includes
a downward recessed, scooped region partially surrounded by a flat
section.
3. The document tray of claim 2, wherein the scooped region extends
to the forward edge of the bottom panel.
4. The document tray of claim 2, wherein the forward edge of the
bottom panel has a rearwardly recessed scalloped region.
5. The document tray of claim 1, wherein a window is located on
each of the back wall and the side walls.
6. The document tray of claim 5, wherein each window extends
downward to the bottom panel and at least partially into a
respective edge of the bottom panel thereby creating an inwardly
recessed edge at each window.
7. The document tray of claim 1, wherein the rear wall leans
slightly creating an acute angle between the bottom panel and the
rear wall.
8. The document tray of claim 7, wherein the acute angle is in the
range of approximately 89 degrees to approximately 83 degrees.
9. The document tray of claim 1, further including a receptacle in
the rim proximate the front edge of each side wall.
10. The document tray of claim 9, further including pair of
receptacles on the side walls and a pair of downwardly depending
ribs disposed on the bottom of the tray near bottom edge of the
side walls, wherein the ribs are configured and oriented to align
with and be received by the receptacles.
11. The document tray of claim 1, further including a rear
receptacle on the rim above the back wall and a rear leg that
extends downward from the bottom of the tray proximate the back
wall.
12. The document tray of claim 1, including a pair of receptacles
on each wall.
13. A document tray comprising: a bottom panel having a pair of
front edges meeting at a front corner, a pair of rear edges meeting
at a rear corner, an upper surface and a lower surface; a pair of
walls extending generally upward from the rear edges of the bottom
panel, each wall leaning at least slightly forming an acute angle
with the bottom panel; a corner post extending generally upward
near the front corner of the bottom panel; two front openings, one
each between the corner post and one of the walls; and a pair of
storage areas defined above the bottom panel and one each between
each wall and the corner post, wherein the pair of storage areas at
least partially overlap near the rear corner.
14. The document tray of claim 13, wherein the bottom panel
includes a downwardly scooped region.
15. The document tray of claim 13, wherein each of the walls
includes a window.
16. The document tray of claim 13, wherein the walls include an
upper rim extending generally outwardly from the top edges of the
walls and including at least one dimple disposed thereon.
17. The document tray of claim 13, including a plurality of feet
disposed on the bottom of the tray and sized and shaped to
stabilize the document tray when placed on a surface.
18. The document tray of claim 17, including a plurality of dimples
on the upper edges of the walls and an upper edge of the corner
post, wherein each of the plurality of feet has a boss on the
bottom thereof.
19. The document tray of claim 18, wherein the corner post is
hollow and open at a bottom thereof.
20. The document tray of claim 19, further including a second like
tray and wherein the document tray is placed adjacent the second
like tray in a stacked in-use condition in which the bosses of the
document tray are received by the dimples of the second like
tray.
21. The document tray of claim 19, further including a second like
tray and wherein the document tray is placed adjacent the second
like tray in a stacked nested condition in which the document tray
is nested at least partly within the storage spaces of the second
like tray and wherein the corner post of the second like tray is
received through the hollow and open bottom of the corner post of
the document tray.
22. A plurality of stackable and nestable document trays each
comprising: a bottom panel having a rear edge, a forward edge, a
pair of opposed side edges and an upper and lower surface; a rear
wall extending upward near the back edge of the base panel and
having a lower edge, an upper edge, and a pair of side edges; a
pair of side walls spaced apart and opposed relative to one
another, one each extending generally upward relative to a
respective one of the side edges of the bottom panel; a storage
space defined above the bottom panel, forward of the rear wall, and
between the side walls; a rim which extends laterally outward from
top edges of the side walls and rearwardly from the upper edge of
the back wall forming a lip on the top edges of the side walls and
the upper edge of the rear wall; a pair of lateral extensions, one
each formed near the forward edge of the bottom panel extending
laterally outward beyond the side edges of the bottom panel and
protruding outward beyond an exterior perimeter of the rim; at
least one receptacle formed in the rim proximate a front edge of
each side wall; and at least one downward facing protrusion on the
bottom of each tray; wherein each of the plurality of trays is
stackable with others of the plurality of trays in both a nested
stacked configuration and an in-use stacked configuration, wherein
the nested stacked configuration includes a first tray disposed at
least partly within the storage space of a second tray and wherein
both the first and second trays are arranged in generally similar
orientations and wherein the pair of lateral extensions of the
first tray are positioned forward of front edges of respective side
walls of the second tray, and wherein the in-use stacked
configuration includes the pair of lateral extensions of the first
tray resting on a portion of the rim above the side walls of the
second tray and wherein a portion of the bottom panel of the first
tray rests on a portion of the rim of the second tray above the
rear wall and wherein the bottom:panel of the first tray is
substantially parallel to and spaced apart from the bottom panel of
the second tray.
23. The plurality of trays of claim 22, wherein the portion of the
bottom panel of the first tray that rests on a portion of the rim
of the second tray is a downwardly depending foot in the stacked
in-use configuration.
24. The document tray stack of claim 22, wherein the protrusion of
the first tray is received by the receptacle of the second tray in
the stacked in-use configuration.
25. The document tray stack of claim 22, each tray including a
plurality of protrusions and receptacles, wherein a pair of the
protrusions rest on the rim within a pair of the receptacles in the
stacked in-use configuration.
26. The document tray stack of claim 22, wherein at least one of
the receptacles is located on the rim above the rear wall and at
least one of the protrusions is positioned near the rear edge of
the bottom panel.
27. The document tray stack of claim 22, wherein the receptacle is
generally oriented perpendicular to the side wall and a way extends
from the receptacle and is oriented generally parallel to the side
wall and the protrusion further includes a key oriented generally
perpendicular to the protrusion, wherein the key rests within the
way in the stacked in-use configuration.
28. The document tray stack of claim 22, wherein the lateral
extensions include an upward concave curve.
29. The document tray stack of claim 22, wherein each document tray
in the plurality of trays includes a pair of spaced apart support
structures affixed to the rear wall wherein the support structures
extend below the bottom panel forming rear feet and the tops of the
support structures bend outward, away from the rear wall forming a
loop and wherein the rear feet of the first document tray are
received by the loops of the second document tray in the stacked
in-use configuration.
30. The document tray stack of claim 22, wherein the lateral
extensions are formed from a part of a continuous piece of wire
that bears against the bottom side of the bottom panel and extends
to the back edge of the bottom panel and steps downward and
rearward to also form a rear foot beyond the rear wall and wherein
the lateral extensions rest on the rim and the rear foot also rests
on the rim in the stacked in-use configuration.
Description
[0001] This patent is related to and claims priority benefit of
U.S. provisional application Ser. Nos. 60/559,312, filed on Apr. 2,
2004, 60/590,146, filed on Jul. 22, 2004, and 60/592,366 filed on
Jul. 29, 2004, and incorporating by reference herein all of the
subject matter disclosed in said prior provisional
applications.
BACKGROUND
[0002] 1. Technical Field of the Disclosure
[0003] This present disclosure is generally directed to document
storage and organizing products, and more particularly to stackable
and nestable document storage trays.
[0004] 2. Description of the Related Art
[0005] Organization and storage trays for documents are known in
the art. These storage trays are intended either for stand alone
use or for being vertically stacked with identical storage trays
for multi-level use. However, such trays are often shipped and
displayed in individual form or in the in-use stacked condition.
Consequently, these known document or storage trays take up a
relatively large amount of retail shelf space and also a
significant amount of space during shipment.
[0006] The consumption of relatively large amounts of retail shelf
space by plastic storage trays is problematic, as retail shelf
space is extremely valuable and manufacturers compete vigorously
for adequate shelf space to display their products. Any inefficient
use of retail shelf space can lead to a manufacturer's products not
being adequately displayed, as well as a reduction in the number of
different products a manufacturer may be allowed to display in a
given retail store. Further, because molded plastic document trays
are relatively inexpensive items, the use of shelf space to display
these items must be efficient.
[0007] Further, because the profit margins for these items can be
relatively small, a means for packaging these items in a compact
manner is important for reducing shipment and handling costs of
such low margin products.
[0008] Typical document storage trays are not nestable with more
than one identical storage tray. To stack a pair of such trays, one
tray must be inverted and rotated 180 degrees relative to the
other. The two trays can then be rested on top of one another, but
no other trays can be nested with these two. Therefore, currently
available document storage trays cannot be compactly stacked
together in groups of more than two (or a pair).
[0009] Often, it is desirable to sell such document storage trays
in groups of more than two to provide more than two levels of
storage or for use by more than one person. Thus, currently
available document storage trays cannot be efficiently displayed,
stored or shipped in groups of more than two. Further, if more than
two trays are packaged together or shipped together, additional
packaging material such as cardboard, Styrofoam, plastic film and
the like must be utilized to prevent product damage from relative
movement between trays from scuffing or scratching during shipment
and handling.
[0010] Because of the limitations of currently available document
storage trays discussed above, their use is typically limited to a
single pair, of stacked trays. While some available designs allow
more than two trays to be stacked on top of each other, the design
of such trays make them expensive to package and ship and
inefficient to display in the retail environment.
[0011] Further, there is no currently available set of stackable
document storage trays that also provide an effective collating
function. Collating can be useful for storing different sizes of
paper,(i.e., 81/2.times.11, A4, 81/2.times.14, 81/2.times.17, etc.)
or for storing documents of different types (i.e., incoming mail,
outgoing mail, invoices, mail directed towards different people,
etc.). Currently available stackable storage tray designs often
require the user to work their way down the stack of trays
searching for a particular paper size or document. A stackable
storage tray system that provides a collating function and that
addresses the space and packaging problems discussed above would
most likely be well received by consumers and retailers.
SUMMARY OF THE DISCLOSURE
[0012] In satisfaction of the aforenoted needs, stackable document
storage trays are disclosed which address one or more of the
aforenoted problems. In one embodiment, a plurality of trays may be
stacked tightly together in a nested configuration for packaging,
shipment, handling and for display in a retail environment. This
embodiment also has at least two in-use stacked configurations
including a vertical stacked configuration where the trays are
stacked vertically one on top of another and a second cascaded
configuration where the trays are stacked on top of each other but
with each successive tray being displaced laterally from the bottom
tray to provide a cascaded or stepped configuration. In this
embodiment, the lateral displacement may be alternated to form a
stacked forward and backward configuration as well.
[0013] Another disclosed embodiment includes a built-in collating
function. In this embodiment, each tray includes only two walls
with two open areas for receiving documents. A corner post
structure is used to separate one receiving area from the other
receiving area. The trays may be stacked in a vertical
configuration and the user can alternate between one receiving area
and the other receiving area upward or downward through the stack
of trays. The collating trays can also be nested for shipping,
storage, and display for sale.
[0014] Other advantages and features of the disclosed embodiments
will become apparent upon reading the following detailed
description and forthcoming claims, and upon reference to the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Certain features and advantages of the present invention
will become apparent upon reading the following description in
conjunction with the drawing figures, wherein:
[0016] FIG. 1 is a top perspective view of one example of a
document tray constructed in accordance with the teachings of this
disclosure.
[0017] FIG. 2 is a bottom perspective view of the document tray
shown in FIG. 1.
[0018] FIG. 3 is a front view of the document tray shown in FIG.
1.
[0019] FIG. 4 is a top view of the document tray shown in FIG.
1.
[0020] FIG. 5A is a cross section taken along line V-V of the
document tray shown in FIG. 1.
[0021] FIG. 5B is a close up perspective view of region A of FIG. 1
taken from above and offset from one of the side walls.
[0022] FIG. 5C is a second close up perspective view of region A of
FIG. 1 taken from below and offset from one of the side walls.
[0023] FIG. 6 is a side view of three document trays as shown in
FIG. 1 as stacked in a nested configuration for shipment, packaging
or retail display.
[0024] FIG. 7 is a side view of three document trays as shown in
FIG. 1 and stacked in a vertical in-use configuration.
[0025] FIG. 8A is a side view of three document trays as shown in
FIG. 1 and cascaded in an in-use configuration.
[0026] FIG. 8B is a perspective view of an alternative embodiment
of a document tray constructed in accordance with the teachings of
the disclosure.
[0027] FIG. 9 is a perspective view of three document trays of an
alternative embodiment and shown in the nested configuration.
[0028] FIG. 10 is a top plan view of the three nested trays shown
in FIG. 9.
[0029] FIG. 11 is a sectional view taken substantially along line
11-11 of FIG. 10.
[0030] FIG. 12 is a perspective view of the trays shown in FIGS.
9-11 and stacked in a vertical in-use configuration.
[0031] FIG. 13 is a top plan view of the trays stacked vertically
as shown in FIG. 12.
[0032] FIG. 14 is a sectional view taken substantially along line
14-14 of FIG. 13.
[0033] FIGS. 15A-15G are, respectively, front perspective, rear
perspective, top, bottom, rear, and front views of another example
of a document tray constructed in accordance with the teachings of
the present invention.
[0034] FIGS. 16A-16D are front, side, and perspective views of an
in-use stack of two of the document trays shown in FIGS.
15A-15F.
[0035] FIGS. 17A-17D are front, side, and perspective views of two
document trays of FIGS. 15A-15F in a nested and stacked
configuration.
[0036] FIGS. 18A-18E are, respectively, front perspective, side,
front, top, and alternate front perspective views of another
example of a document tray constructed in accordance with the
teachings of the present invention.
[0037] FIGS. 19A-19D are trays as shown in FIGS. 18A-18E in a
stacked and nested configuration.
[0038] FIGS. 20A-20D are trays as shown in FIGS. 18A-18E in a
stacked configuration.
[0039] FIGS. 21A-21D are trays as shown in FIGS. 18A-18E in a
stacked and cascading configuration.
[0040] It will be understood that the drawings are not to scale and
that, in some instances, details which are not necessary for an
understanding of the disclosed embodiments or which render other
details difficult to perceive, may have been omitted. It should be
understood, of course, that this disclosure is not limited to the
embodiments specifically illustrated in the drawings.
DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS
[0041] A letter tray or document storage tray device, hereinafter
described as a document tray, for storing papers, files, documents,
and the like, for storing and organizing such articles in a
horizontal orientation is shown and described. The disclosed
document trays can be stacked with like or identical storage trays
during use in order to provide multiple storage levels.
Alternatively, the disclosed trays can nest with one another in an
alternative stacked configuration to reduce the amount of retail
display shelf space and shipping space that is required of a large
number of the document trays. The disclosed document trays can be
both stacked and nested with a plurality of like trays so that when
packaged and shipped or when on display for sale to consumers, the
document trays take up relatively little shelf space and much less
space than traditional document trays of similar type. Obviously,
shipping costs are also reduced.
[0042] In at least one embodiment, the trays may be stacked in a
cascaded or staggered orientation so that the forward edge of one
tray is horizontally offset from the forward edge of a tray
disposed therebelow or, conversely, the forward edge of the bottom
tray is horizontally offset from the forward edges of the trays
disposed thereabove. In at least one other embodiment, instead of
the "cascaded" function described above, the trays can be designed
with two open sides arranged at an angle relative to one another,
such as at generally right angles or 90.degree. from each other,
thereby allowing the user to make controlled or collated stacks of
documents. Specifically, proceeding from the bottom or top of a
stack of this type of trays, the user can alternate into which side
the documents are inserted thereby providing an alternating or
collating function to storing documents.
[0043] Referring now to the drawings, FIGS. 1-8B illustrate one
disclosed document tray 20 constructed in accordance with the
teachings of this disclosure. In this example, the document tray 20
is intended to hold letters, files, papers, and the like in a
transverse, horizontal orientation wherein the long dimension of
the paper is the lateral dimension inside the tray 20. As will be
evident to those having ordinary skill in the art, the disclosed
document or letter trays 20 can be alternatively configured to hold
letters, other documents (not shown) or paper in a standard
longitudinal orientation. In such a configuration, the tray 20
would have a longer depth than width. In the disclosed example, the
document or letter tray 20 has a depth that is shorter than its
transverse width to accommodate transversely oriented papers or
documents.
[0044] In the disclosed example, the document tray 20 has a
generally horizontally oriented base panel 22 and a back wall 24
with a bottom edge that is coupled to and extends generally upward
from a back edge 26 of the base panel. The tray 20 also has a pair
of spaced apart and opposed side walls 28 with bottom edges that
are coupled to respective side edges 30 of the base panel 22. The
side walls 28 extend generally forward from respective side edges
or corners 32 formed at the junction between the back wall 24 and
side walls 28 and extend generally upward from the side edges 30
(see FIG. 4) of the base panel 22.
[0045] In this example, a storage receptacle or space 33 (FIG. 4)
is formed within the space above the base panel 22, forward of the
back wall 24, and between the side walls 28. A front opening 34
(FIG. 4) is formed between the exposed front ends 36 of the side
walls 28 above a forward edge 38 of the base panel 22. The front
opening 34 permits forward insertion and removal of documents,
papers, and the like in the storage receptacle space 33. A top
opening 40 (FIG. 5A) is defined rearward of the front opening 34,
between opposed top ends 42 of the side walls 28, and forward of an
upper edge-44 of the back wall 24. The top opening 40 is also
available for insertion and removal of articles in the storage
receptacle 33. In this example where a single tray 20 is being
used, the entire top opening 40 and front opening 38 are clear and
unencumbered. However, this is not the case for some configurations
where multiple trays 20-are stacked as shown below in FIGS. 7, 8A,
and 8B.
[0046] Also, a portion of the top opening 40 can be covered by a
short depth top wall (not shown) connected to the back wall and
spanning between the side walls. A portion of the front opening can
include an optional barrier or front wall (also not shown), which
can extend to a height less than the height of the adjacent side
walls 28. The front wall and/or the top wall can be optionally
provided to assist in retaining documents within the front opening
34 and the storage receptacle 33 without first being grasped by a
user. The front wall can also be provided as a depth of nesting
stop or limiter, if desired.
[0047] FIG. 2 illustrates a bottom perspective view of the document
tray 20 of FIG. 1. As shown in both FIGS. 1 and 2, the base panel
22 is a generally flat panel, though it need not be perfectly flat
or planar. In the present example, a flat section 50 defines a
majority of the base panel 22 in this example and extends around a
perimeter of the panel adjacent the side walls 28 and back wall 24.
The base panel 22 in this example also includes an optional,
downwardly recessed, scooped region 52 that is centrally disposed
within and surrounded on three sides by the flat section 50. In
this example, the scooped region 52 extends only part way rearward
toward the back wall 24, but extends all the way forward to the
forward edge 38 of the base panel 22. The forward edge 38 also
includes an optional scalloped area 54 that is scalloped or
recessed toward the back edge 26 of the panel 22. The width of the
scalloped area 54 coincides in this example with the width of the
scooped or indented region 52. However, the optional scalloped area
and scooped regions, if provided, can be of different width and can
vary in configuration and construction from that shown in FIGS. 1,
2, and 4.
[0048] The scooped region 52 can be added to provide some
structural stability and rigidity to an otherwise flat base panel
22. The scooped region 52 can also be provided to assist a user in
grasping documents or other articles stored within the storage
receptacle 33. The scooped region 52 is recessed downwardly to
create a small gap between an upper surface of the flat region 50
of the base panel 22 at the location of the scooped region 52 and a
document or other article stored on the base panel 22. The space or
gap will permit one to easily get beneath and lift the article. The
scalloped area 54 can also be provided to expose a portion of an
object or document in the storage receptacle 33 extending forward
of the base panel forward edge 36 at the scalloped area 54. One can
then easily grasp the exposed portion of the object.
[0049] The scooped or indented region 52 in this example extends
more than half way into the depth of the base panel 22 and extends
slightly less than half of the base panel 22 width. The disclosed
scooped region 52 has a curved rearward end and generally straight
sides extending from the curved end to the forward edge 38.
However, as will be evident to those having ordinary skill in the
art, the scooped region 52, if provided, can vary in configuration,
size, and construction without departing from the spirit and scope
of the present invention. If provided, the scooped region 52 can be
of limited width so as to permit the flat section 50 of the base
panel 22 to support an entire object in a flat condition, thus
creating the gap at the scooped region.
[0050] The base panel 22 can also be provided with ribs or other
structures, formations, or the like on both or either of the upper
surface or the lower surface. Such ribs or other formations can add
structural rigidity and strength to the otherwise flat base panel.
If raised ribs or other formations are provided on the upper
surface of the base panel 22, these structures can also assist in
elevating documents or other articles stored in the storage
receptacle 33 above the base panel 22. This feature can be included
to create a gap between the base panel and the stored objects so
that he objects can be easily grasped and lifted from the document
tray 20.
[0051] In the disclosed example of FIGS. 1-8B, the back wall 24 is
shown to include an optional window or opening 60. The side walls
28 are also shown to include optional openings or windows 62. A
front view of the document tray 20 is shown in FIG. 3 and best
illustrates the window 60 in the back wall 24. The perspective
views of FIGS. 1 and 2 illustrate the windows 62 in the side walls
28. Though each wall of the tray 20 is shown having one window 60
or 62, one or more of the walls need not have any windows or can
have two or more windows as desired. The number, size, shape, and
location of the windows 60, 62 can vary considerably to provide a
desired function and/or aesthetic appearance, and yet fall within
the spirit and scope of this disclosure.
[0052] In the example of FIGS. 1-8B, each of the windows 60 and 62
extends across a portion of a width of each respective wall 24, 28
and part way, but not completely, toward the top edges 42 of the
side walls and top edge 44 of the back wall 24. However, each
window 60, 62 extends-all the way down to the back edge 26 of the
base panel 22 and to the side edges 30 of the base panel 22 as
shown in FIGS. 1-5. If desired, each window can also extend partly
into the respective edge of the base panel 22 to create a scallop
or inwardly recessed edge. The one or more windows 60 and 62 can be
optionally provided to create a desired esthetic appearance, as
noted above. However, the windows 60 and 62 can also be provided to
reduce weight of the tray 20, to provide a view into the storage
receptacle 33, to provide a handhold for carrying the tray, and/or
to reduce cost per unit based on material reduction.
[0053] FIG. 4 illustrates a top view of the document tray 20 and
FIG. 5A illustrates a longitudinal section through the tray 20. In
the disclosed example, the side walls 28 diverge slightly away from
one another in two dimensions. The side walls 28 diverge away from
one another moving forward from the back wall 24 toward the front
ends 36 of the side walls. The side walls 28 also diverge from one
another moving upward from the base panel 22 toward the top ends 42
of the side walls. The storage receptacle 33 thus becomes wider
toward the top opening 40 (FIG. 5A) and toward the front opening 34
(FIG. 4) in this example. Thus, the side walls 28 define a draft
both in an upward vertical direction and in a forward horizontal
direction.
[0054] As shown in FIG. 5A, the back wall 24 in this example leans
slightly forward relative to a vertical reference toward the
forward edge 38 of the base panel 22. However, the back wall 24 can
alternatively lean rearward, away from the front edge 38 of the
base panel. A rim 70 extends laterally outward from the top ends 42
of the side walls 28 and rearwardly from the upper edge 44 of the
back wall 24. The rim has an upward facing or upper surface 72 and
in this example is a continuous rim or lip extending around the
side walls 28 and back wall 24. The rim 70 can add strength and
rigidity to the tray structure and can provide additional functions
as described below.
[0055] The forward lean angle of the back wall 24 can be from about
1.degree. to about 5-7.degree. in this example, but the angle can
vary. The front ends 36 of the side walls 28 can similarly lean
slightly forwardly at the same angle, as in this example, also
relative to a vertical reference. The forward edge 38 of the base
panel 22 extends forward beyond the position of the front ends 36
of the side walls 28 at the point where they meet to provide front
ledges or lateral extensions 76. In this example, the forward edge
38 extends forward beyond upper front corners 74 of the side walls
as shown in the top view of FIG. 4. The lateral extensions 76 of
the base panel 22 also extend laterally outward beyond the side
edges 30 of the base panel 22 as best seen in FIGS. 1 and 4. These
lateral extensions 76 also extend outward a distance slightly
beyond the exterior perimeter edge 78 of the rim 70 at the location
of the lateral extensions 76, as can be seen in FIG. 4. Structural
support for the lateral extensions 76 is provided by a
corresponding pair of laterally extending and vertically oriented
buttresses 80 that project outward from the side walls 28 at the
front ends 36 and upward from the extensions (See FIGS. 1 and
3).
[0056] In the example of FIGS. 1-8B, each side of the rim 70 has a
pair of receptacles or notches 82, 84 in the upper surface 72 near
the respective front corners 74 of the side walls 28. Each pair of
notches 82, 84 includes a front notch 82 and a rear notch 84
recessed downwardly into the upper surface 72 of the rim 70. As can
be seen in the top view of FIG. 4, the notches 82, 84 in this
example are orientated at a slight angle relative to a transverse
access of the tray 20. This is to accommodate stacking with other
of the trays 20 as shown in FIGS. 7 and 8A.
[0057] As best seen in FIGS. 5B and 5C, the notches 82, 84 each can
include a respective channel or way 81, 83 oriented generally
perpendicularly to the notches 82, 84 and extending forward towards
the front ends 36 of the side walls 28. The channels 81, 83 are
sized and shaped to receive a key 85 extending forward from a
protrusion or rib 86 on the lower surface of the base panel 22.
This configuration of the channel 81, 83 and the key 85 serves to
laterally strengthen the side walls 28 when like document trays are
stacked. Because the side walls diverge slightly from a vertical
plane, when a like document tray is placed on top of another like
document tray a torsional load is generated at the base of the side
wall. The channels 81, 83 and keys 85 interlock in such a way as to
effectively transfer the torsional load at the base of the side
wall of the lower document tray into a tensile load along the
bottom panel of the upper document tray, thereby laterally
strengthening the stacked combination. Also, the channels 81, 83 in
cooperation with the keys 85 will assist in retaining relative
lateral alignment of stacked trays.
[0058] FIG. 6 shows a cross section taken longitudinally through a
tray 20 and bisecting the notches 82 and 84 of one side. The ribs
86 depend downward as a continuation of each of the buttresses 80
on the sides of the tray 20. Depending upon the stacking
configuration desired, as discussed below, the rib 86 is configured
and oriented so that it aligns with and can be received in a
selected one of the notches 82 or 84. A key 85 will then be
received in the channel 81, 83 of each select notch 82 or 84.
[0059] As shown in FIGS. 4 and 5A, rear notches or receptacles 88
are provided in the upper surface 72 of the rim 70. Alternatively,
a single, centrally located rear notch 88 can be used. The rear
notch 88 can be either blind recesses or through-openings. As seen
in FIG. 5A, corresponding depending rear protrusions or legs 90
extend downward from, and are a continuation of, the back wall 24
below a level of the base panel 22. The rear legs 90 are sized to
be received in the rear notches 88 in one of the stacking
configurations described below. As shown in FIGS. 2 and 5A,
additional legs are provided extending downward from the tray.
These include a pair of rear legs 92 extending downward as
continuations of the side walls 28 near the back wall 24 and a pair
of side legs 94 extending downward as continuations of the side
walls 28 near the front of the tray and positioned just behind the
buttresses 80 in this example. The legs 92 and 94 are positioned
adjacent the windows 60 in the side wall 28. These legs 92, 94
extend downward to the same level or height as the rear legs 90. A
downwardly depending lip 96 extends from the forward edge 38 of the
base panel 22 and also is of the same height as the legs 90, 92,
and 94. Thus, the legs 90, 92, 94 and the lip 96 provide a stable
base for the tray 22 to rest on a horizontal surface.
[0060] FIGS. 6-8A illustrate three possible stacking and/or nesting
configurations that can be produced utilizing the document tray 20
shown in FIGS. 1-5A. As shown in FIG. 6, the document trays 20 (in
this case, three trays 20) are stacked and nested relative to one
another to produce a compact, stable stack of trays 20 when not in
use but when being shipped, stored, or displayed for sale. The side
walls 28 and back wall 24 of one tray 20 are received and nested
within the storage receptacle 33 of a lower tray in this example.
The buttresses 80 of one tray are positioned forward, offset
upward, and adjacent the buttresses 80 of a lower tray 20 and the
forward extensions 76 of the base panel 22 of one tray will rest
neatly on the forward extension 76 of the lower tray 20.
[0061] The angle of the front ends 36 of the side walls 28 and the
back wall 24, as well as the extension distance of the rim 70,
produces the novel result of the three permissible stacks shown in
FIGS. 6-8A. When multiple trays are vertically aligned, they are
vertically stacked in an in-use configuration. When a plurality of
trays 20 are stacked cascading or offset rearwardly, they also
produce an in-use configuration with a rear cascading orientation.
The rear cascading orientation permits easy access to documents or
other objects stored in any given tray. If a plurality of trays 20
are stacked relative to one another and offset progressively
forward, they will nest within one another as shown in FIG. 6.
[0062] The document trays 20 can be stacked on top of one another
so that a space having a depth approximately the height of the side
walls and back wall is defined between the stacked document trays
20 as shown in FIGS. 7 and 8A. The disclosed trays 20 can be
stacked either in a generally vertical orientation (FIG. 7) or a
rearwardly cascading orientation (FIG. 8A). Specific features of
the disclosed document trays permit these alternative stacking
and/or nesting arrangements.
[0063] As shown in FIG. 7, when a generally vertical stack of the
trays 20 is desired, the rib 86 of one tray is received in the
forwardmost notch 82 in the top surface 72 of the rim 70 of a
second tray 20 beneath it. The angle of the forward edge 36 of the
side walls 28 is such that the rib 86 and front notch 82 vertically
align with one another on one tray. Thus, the vertical stack can be
achieved with two or more trays 20. At the rearward end, the rear
leg 90 and the rear notch 88 on a given tray 20 are also vertically
aligned. Thus, the leg 90 of one tray will rest in the rear notch
88 of a lower tray when vertically stacked as shown in FIG. 7.
[0064] As shown in FIG. 8A, a cascading vertical stack can also be
achieved utilizing the trays 20 disclosed herein. When stacking the
trays in this configuration, the rib 86 is positioned in the notch
84 of a tray 20 beneath it. The notch 84 of one tray is rearwardly
and vertically offset from the rib 86 of the same tray. Thus, when
two trays 20 are stacked with the rib 86 positioned in the notch 84
of another tray, the trays 20 will be cascading, i.e., offset
rearward relative to one another.
[0065] When stacked in this configuration, a bearing surface 98
positioned longitudinally rearward of the rear legs 92 bears
against the upper surface 72 of the rim 70 of the lower tray 20.
The legs 92 will be captured within the boundary of the side walls
28 of the lower tray as a result of the upward and outward side
wall divergence. The rear leg 90 will be positioned outside the
boundary of the rim 70 in this configuration.
[0066] The size and shape of the tray 20 as well as the wall 24, 28
height can vary considerably without departing from the spirit and
scope of this disclosure. The configuration, shape, number, and
position of the windows 60 and 62 as disclosed herein can vary
considerably as well. No windows need be provided. Further, the
base panel 22 can be perforated and/or include windows of its own
for material reduction and/or to achieve desired
characteristics.
[0067] The windows, 60, 62, if provided, can also be configured to
act as handles for the document tray. A user can simply grasp a
tray, whether empty of loaded, by one of the windows and place
their fingers though that window making the document tray 20 easier
to carry.
[0068] FIG. 8B illustrates a perspective view of an alternative
embodiment of a document tray. The embodiment of FIG. 8B differs
from the embodiment of FIGS. 1-8A in that the document is inserted
into the storage space longitudinally instead of laterally.
Therefore, the document tray is greater in depth than in width.
Otherwise, the structure and elements of this embodiment are
substantially the same as for the embodiment of FIGS. 1-8A and are
assigned like reference numerals.
[0069] Another alternative embodiment of a document tray 120 is
disclosed in FIGS. 9-14. The tray 120 has a separate collating
feature in addition to the nesting and vertical stacking functions.
Specifically, turning to FIG. 9, three stacked and nested trays 120
are shown. Each tray 120 has a generally horizontal base panel 122
including scooped regions 152a, 152b and a generally flat portion
150. The base panel 122 is connected to two vertical walls 128 that
extend upward from the side edges shown at 130 and which form a
rear corner shown at 132. Each wall 128 also includes a window 162
and a plurality of recesses shown generally at 164 that are bound
by reinforcing rib structures 165. Each wall 128 terminates at an
upper surface or edge 172 and has a downward extending recess or
detent 166. In addition, the rear corner 132 also includes a detent
or dimple 166 in the upper edge 172.
[0070] A front corner post structure 167 is formed from a pair of
buttresses 180 that extend upward from the base panel 122. As shown
in FIG. 11, the buttresses 180 are hollow and, in the nested and
stacked position shown in FIG. 11, enable the trays 120 to be
neatly and tightly stacked together. The corner post 167 also
includes a detent or dimple 166 in the top surface. A storage space
is formed above the base panel 122 and between the side and back
walls 128 and the side and front edges of the base panel 122.
[0071] As shown in FIG. 11, to place the trays 120 in the nested
position, the corners 132 and hollow buttresses 180 are vertically
aligned so that one tray 120 sits on top of and drops down just
inside a lower tray.
[0072] FIG. 11 also illustrates a rear foot 192 disposed beneath
the corner 132 on each tray and one set of front feet 194 disposed
beneath the side walls 128. In addition, another front foot 195 is
disposed beneath the corner post structure 167 on each tray 120.
Thus, each tray 120 has a rear foot 192, two front feet 194, and a
front corner foot 195 for stability when a single tray 120 or a
lower tray 120 of a stack is placed on a support surface. Each foot
192, 194, 195 has in this example a downwardly protruding boss, all
of which are shown at 193. Also shown in FIG. 11 is the plurality
of dimples 166 in the top edges of the corners and side walls for
receiving the bosses 193 in the stacked configuration shown in FIG.
14. To place the trays 120 in the vertically stacked position shown
in FIGS. 12-14, the bosses 193 of an upper tray are aligned with
their respective dimples 166 of a tray beneath the upper tray, and
then the upper tray is stacked on the lower tray.
[0073] An additional feature of the trays 120 as shown in FIGS.
12-14 is that the corner posts 167 define two discrete front
openings 134a, 134b separated by the post structures 167 which
access one of two storage areas 135a and 135b. The storage areas
135a and 135b at least partially overlap near the back corner 132.
Thus, a user can alternate between the openings 134a shown at the
left in FIG. 12 and the openings 134b shown at the right in FIG. 12
when, for example, using the trays 120 to store different sizes of
paper or different types of documents. Of course, other uses for
the configuration shown in FIG. 12 are also foreseeable. The
collating feature can be taken advantage of by using the front
opening 134a of a first tray 120 and using the alternate opening
134b of a second tray 120 disposed either below or above the first
tray 120.
[0074] As shown in FIG. 14, the bosses 193 fit neatly within the
dimples 166 to provide a stable structure thereby enabling two or
more trays 120 to be arranged in a given stack configuration. The
corner post structure 167 with its hollow buttresses 180 also
provides stability to the stacked configuration shown in FIG. 14
thereby eliminating the need for a third wall so that only the two
side walls 128 need to be used with the rear corner 132. Additional
stability to the structure is provided by the foot 195 and/or the
wall that connects the hollow buttresses 180 of the corner post
structure 167.
[0075] Similar to the tray 20 discussed above in connection with
FIGS. 1-8A, the tray 120 includes scalloped areas 154a, 154b in the
forward edges of the bottom panel at the pair of front openings.
However, the side walls 128 include arched front ends 136 as
opposed to the inwardly slanted front ends 136 and buttresses 80 as
shown in FIGS. 1-6. Further, the foot or ledge 195 that extends
between the buttresses 180 also includes a reinforcing upwardly
protruding lip 199 for additional structural reinforcement.
[0076] Numerous modifications and alterations may be made to the
design of the tray 120 shown in FIGS. 9-12. Specifically, the
design of the corner post structure 167 can be modified greatly
using a single post structure, a single hollow buttress 180, a
single hollow column, a hollow cone, or the like. Comer structures
can also be used as a substitute for the walls 128, and the windows
162 can either be enlarged or made smaller. In short, numerous
design alterations can be employed to provide a stackable document
tray 120 with a collating function described herein. The collating
tray 120 in this example can both stack and nest, but does not
cascade in a stacked configuration.
[0077] FIGS. 15A-15G depict another example of a document tray 250
constructed in accordance with the teachings of the present
invention. The tray 250 is also stackable and nestable, but is
unable to cascade. In this example, the document tray 250 is
constructed from wire and mesh materials and has a bottom panel
252, side walls 254, and a rear wall 256, each constructed
essentially of a mesh material. A wire structure is provided to
support the mesh and to give the tray rigidity and strength.
[0078] In this example, the tray 250 has a pair of laterally
outwardly extending wire-form lateral extensions or ears 260
positioned near a front end of the tray 250. Each of the ears 260
has an upwardly concave curve 262. Each tray also has a downturned,
curved front edge 264 of the bottom panel 252. Each tray 250
further has a pair of spaced apart wire-form structures 266
attached to the rear wall 256 in laterally spaced apart relation.
The bottom of each structure 266 extends below the bottom panel,
forming a pair of depending wire loop rear feet 268. The tops of
the structures bend outward and spaced away from the rear wall 256
to form a pair of rearwardly protruding wire loops 270. Each loop
270 creates an aperture 272 carried near the upper end of the rear
wall. Each distal end of the front ears 260 terminates at a
downturned front foot 274 that extends below the bottom panel 252
about the same distance as the rear feet 268. When in use, the tray
250 can rest on the feet 268, 274 on a support surface.
[0079] The wire support structure of the tray 250 includes a pair
of side wall top wires 276, one running along each side wall 254. A
rear wall top wire 278 runs along the top edge of the rear wall
256. The loops 270 and apertures 272 are spaced outward of the rear
wall top wire 278. As in prior examples, the side walls 254 taper
outward away from one another and the rear wall is tilted slightly
inward. However, the rear wall need not be tapered or tilted inward
but instead can alternatively be vertical or taper outward if
desired. Further, in this example, the side walls do not diverge
away from one another moving toward the front of the tray. Instead,
the side walls are the same distance apart from the back wall to
the tray front.
[0080] Turning to FIGS. 16A-16D, the tray 250 can be vertically
stacked with one or more like trays 250. The concave curve 262 of
each of the front feet 274 of an upper tray 250 receives and rests
on the top wire 276 of one of the side walls 254 of a lower tray
250. The rear feet 268 of the upper tray drop into corresponding
ones of the apertures 272 of the loops 270 in the wire structures
266 on the rear wall of the lower tray. In this configuration, the
trays 250 can be vertically stacked for use.
[0081] As shown in FIGS. 17A-17D, the tray 250 can be stacked and
nested with one or more like trays 250. The ears 260 of the upper
tray can be positioned forward of the respective front edges 280 of
the lower tray to nest on the bottom panel of the lower tray. The
rear feet 268 of the upper tray rest on the bottom panel 252 of the
lower tray. Each of the wire-form ears can have a bend forming a
front foot 274 that extends downward to about the same distance as
the rear feet 268. The front foot 274 on each ear 260 of the upper
tray rests on the bottom panel 252 of the lower tray. Thus, the
front feet 274 and rear feet 268 can be sized to prevent side and
back walls of the nested trays from frictionally engaging with one
another when stacked and nested. A consumer can easily remove one
of the nested trays 250 and replace it if desired with little
effort. The front edge 264 can be curved downward to render it easy
to grasp the tray 250 and also to present documents stored therein
for easy retrieval.
[0082] The ears 260 need not be wire-form. Instead, the ears can be
bent, curved, solid tabs extending outward from the sides of the
tray. Also, the structures 266 on the rear wall of the tray 250
need not be wire form. The structures can also be solid, flat
strips of material, bent to form an upper receptacle to receive
therein the rear feet of a tray stacked on top of the tray.
[0083] Turning to FIGS. 18A-18E, a document tray 300 is shown that
is similar to the tray 250 in that it is a wire and mesh
construction. The wire configuration is altered in this example and
given new reference numbers. The mesh walls are essentially the
same and, thus, are given like reference numbers. In this example,
the document tray 300 is constructed from wire and mesh material
and has a bottom panel 252, side walls 254, and a rear wall 256,
each constructed essentially of mesh material. A flat wire
structure is provided to support the mesh and to give the tray
rigidity and strength.
[0084] In this example, the tray 300 has a pair of outwardly
extending wire-form lateral extensions or ears 302. Each of the
ears 302 has a stepped configuration terminating at a horizontal
front foot portion 304. The front foot portion 304 extends below
the bottom panel 252. The tray 300 also has a bottom wire loop 306
that extends around the bottom of the tray generally within the
perimeter of the bottom panel 252. The wire loop 306 forms the feet
304 and ears 302. A rear bar 308 of the wire is stepped downward at
stepped portions 309 from side bars 310 of the wire loop. The
stepped portions 309 extend rearwardly and the rear bar 308 extends
laterally across the tray 300. The rear bar 308 is spaced outwardly
a distance from a plane of the rear wall 256. The rear bar 308 is
positioned a distance below the bottom panel 252 about the same
distance as the front foot portions 304. During use, the tray 300
can rest on the rear bar 308, stepped portions 310, and foot
portions 304 on a surface.
[0085] The top wire 312 of each side wall 254 has a pair of front
depressions 314 and 316 formed therein near the front edge of each
side wall. The first depression 314 is spaced forward of the second
depression 316. The top wire 318 of the rear wall 256 also has a
pair of spaced apart depressions 320 formed therein and spaced
apart along the top wire. As can be seen in FIGS. 19A-D, when two
or more trays 300 are stacked and nested, the foot portions 304 of
an upper tray sit forward of the front edge of the side walls 254
of a lower tray and rest on side supports 322 that rise from edges
of the bottom panel 256 forward of the side walls 254. The rear bar
308 rests on the bottom panel 252 of the tray 300 as shown in FIG.
19B.
[0086] As shown in FIGS. 20A-20D, when two or more of the trays 300
are vertically stacked, one of the pair of spaced apart wires
forming the foot portion 304 rests in the first depression 314 in
each side wall top wire. The wires of the stepped portions 310 rest
in a respective one of the rear depressions 320 as shown in FIGS.
20C and 20D. As shown in FIGS. 21A-21D, when two or more of the
trays are stacked and cascaded, one of the pair of spaced apart
wires of each of the foot portions 304 rests in a respective one of
the front and rear depressions 314 and 316 in each side wall top
wire. The elongate wires of the stepped portions 310 simply shift
rearward in relation to the rear depressions 320, but rest
therein.
[0087] As will be evident to those having ordinary skill in the
art, the wire and mesh configurations shown herein are merely
examples of many variations and modifications that can be made to
the document trays disclosed herein. In one example, the trays can
stack and nest. In another example, the trays can stack, nest, and
cascade. In a further example, the trays can stack, nest, and offer
collated storage. The means to accomplish such tray features can
vary considerably and yet fall within the spirit and scope of the
invention. The rear walls can have one, two, or three or more
notches, loops, or other features to facilitate stacking. The side
walls can have a wide variety of notches, depressions, or the like
to also facilitate stacking and cascading, as desired. The rolled
mesh front edge can be added to provide rigidity as well to the
structure.
[0088] Merchandisers and retailers of horizontal orientation
document or letter trays typically provide shelf space and
arrangements that vary from store to store and from retailer to
retailer. Thus, a product configuration that is suitable for
display in a shelf space at one store or retailer may not be
suitable for a shelf space or configuration at another retailer or
store. The disclosed document trays permit stacking and nesting of
a large number of the products. The disclosed document trays can
thus be displayed, packaged, shipped, stocked, stored, and the like
within a relatively small amount of shelf space.
[0089] By maximizing packaging and shipping space as well as store
shelf space by utilizing the disclosed tray configurations, one is
able to ship and store a larger product volume per unit area. This
creates more space within an existing product display in a limited
shelf storage space that may have been originally suited for a
completely different product. This can increase revenue dollars for
the retailer per square foot of shelf space. The tight nesting
products may also permit adding the disclosed document trays to an
existing store shelf space without having to knock out another
product from that same shelf space.
[0090] Document trays for storing items such as files, papers,
letters, or the like in a horizontal orientation have not
heretofore been designed having the nesting, stacking, and optional
cascading and collating characteristics disclosed herein. Some
solutions have been provided, but these typically require that the
trays offered for sale be separately packaged or packaged only in
pairs. Such products typically are packaged to protect the articles
from being damaged by one another while being shipped or while on
display for sale. Because a typical tray of this type does not
tightly nest with like trays, the trays can become scuffed,
scratched, or the like as they move and bang into one another.
[0091] In contrast, the disclosed tray configurations may eliminate
the need for utilizing foam, paper, corrugated elements, poly bags,
or other such packing materials. Instead, the disclosed document
trays can be shipped, stored, and displayed in tightly nested
stacks. The stacks will provide stability to the shipped, stored,
and displayed products. The products can stand alone without
additional packing both in shipping containers and on a retailer's
shelf storage space.
[0092] Some other existing office products of the type described
herein are capable of nesting, unlike that disclosed here and with
only one other like product. The two products must be inverted or
turned upside down and rotated 180 degrees relative to one another
in order to nest. If nestable, existing document trays are not
known to offer the stacking options of the trays disclosed here.
These known tray products also must still utilize additional
packaging to prevent the products from moving relative to one
another, which would otherwise cause scuffing or scratching. Such
known products do not typically optimize product nesting and reduce
shelf space to the degree accomplished by the disclosed document
trays.
[0093] The disclosed document trays substantially reduce the
necessary space required for shipping, storage, and retail sale,
yet maintain the standard function for document tray products. The
standard function is typically known to be that of horizontally
storing letters, document, papers, files, folders, magazines, and
other like sized objects. The disclosed trays can nest with one
another while still meeting the aforementioned function and
minimizing the possibility of product damaged during shipping.
[0094] The materials and processes used to manufacture the
disclosed trays can vary considerably and yet fall within the
spirit and scope of the present invention. However, in one example,
the document trays disclosed herein can be manufactured using an
injection molding process. The materials utilized in one example
can be commodity plastics such as polystyrene or polypropylene.
However, many other materials may be suitable for forming the
disclosed tray configurations. For example, other materials may
include engineering grade plastic materials such as polycarbonate,
ABS or TPE. Other commodity thermoplastics, or even further
alternative materials such as metal, wood, organic materials,
leather, glass, or variations and combinations of these materials,
as well as other secondary fabrics and woven materials. Material
selection may assist in creating a higher impact strength,
flexibility, improved resistance to scratching or scuffing, or
enhanced appearance. The material selection can be undertaken with
important characteristics in mind for a given application. However,
engineering plastics such as polystyrene or polypropylene also lend
themselves to reduce consumer cost.
[0095] The disclosed document trays can be painted, decorated, or
in-molded with labels, graphics, or other layers or accents. These
additional design characteristics can be employed to protect the
surfaces of the document tray or to enhance the decorative nature
of the product. Combinations of materials can be utilized and
assembled in any suitable way, including forming a plastic
underbody product with rubber over-molded on the plastic base
material. Alternatively, metal parts can be mechanically fastened
together or wood products can be covered with suitable decorative
materials such as fabric, metal decorative and protective corner
features, and the like.
[0096] Depending upon the materials selected, the manufacturing
processes and methods used can also vary and be employed as needed.
In one example, a plastic document tray disclosed herein can be
molded using a simple two part mold. The draft angle of the side
walls 28, 128, front edges 36, 136, and back wall 24 provide the
necessary mold draft for easy formation and removal of parts from
the mold cavities. The windows 60, 62, 162 in the walls 24, 28, 128
can be formed by providing shut-offs or surface to surface metal
contact within the mold. By extending the windows 60, 62, 162 into
both the side and back walls 24, 28, 128 and at least slightly into
the bottom panel 22, 122, the shut-off can be provided and yet
permit easy mold separation and part removal. The disclosed
document tray configurations should be molded with mold separation
occurring at an angle relative to a reference that is perpendicular
to the base panel. This is because the back wall 24, 124 leans at
an angle slightly inward toward the storage receptacle 33, 133. The
mold separation direction should be such that the back wall 24, 124
is tilted at a slight draft angle away from the mold separation
axis or direction.
[0097] The disclosed trays improve upon maximizing retail shelf
space, accommodate variable shelf space and configurations, and
enhance product nesting shipping, stock storage, and display for
sale. Product nesting is accomplished in a slightly bi-directional
manner whereby each tray is stacked vertically upward and offset
slightly horizontally forward relative to its preceding tray in a
stack. The stacked trays can be displayed and shipped without
damage to the product due to scuffing, scrapping, and the like
because the products will:be tightly nested. Additional packing can
be negated. A number of the disclosed trays can also accommodate
two alternative in-use stack orientations. These trays can be
stacked in either a vertical in-use configuration or in a rearward
cascading in-use configuration.
[0098] Additionally, freight cube size can be optimized and
significantly reduce utilizing the disclosed nested document tray
configuration. Products shipped in bulk can be directly unloaded
from the master carton or shipping box onto a shelf. No additional
reorientation of the product may be necessary, making the
merchandiser's handling of the product easier. The nested trays
also assist in retaining the displayed trays on a retail shelf
space. The trays also look more organized when nested as disclosed
herein. This reduces the amount of work required by the
customer/merchandiser to keep the shelf display organized and
arranged. An organized shelf space may effect the perception of the
consumer and influence his or her decision to buy the displayed
products.
[0099] Further, because more product can be displayed for sale in a
given amount of shelf space, less restocking time and stocking
space is necessary for the retailer. Having more product available
for sale at any one time reduces the frequency of an item appearing
to be out of stock, which can prevent a consumer from leaving the
establishment to go elsewhere to find the desired product.
[0100] Although certain document trays that are nestable and
stackable have been described herein in accordance with the
teachings of the present disclosure, the scope of coverage of this
patent is not limited thereto. On the contrary, this patent covers
all embodiments of the teachings of the disclosure that fairly fall
within the scope of permissible equivalents.
* * * * *