U.S. patent application number 13/178611 was filed with the patent office on 2012-01-12 for packaging tray and method of use.
Invention is credited to Christopher N. Waldrop, David R. Waldrop, Michael W. Waldrop.
Application Number | 20120005992 13/178611 |
Document ID | / |
Family ID | 45437560 |
Filed Date | 2012-01-12 |
United States Patent
Application |
20120005992 |
Kind Code |
A1 |
Waldrop; Christopher N. ; et
al. |
January 12, 2012 |
Packaging tray and method of use
Abstract
A packaging system for packaging food on a plurality of trays is
provided. The packaging system has a main conveyor configured to
move each of the plurality of trays about the packaging system and
a tray unloader for unloading one tray from a tray stack onto the
main conveyor. The packaging system has a food loader configured to
place the food into each of the trays and a food accessory loader
configured to place a food accessory into a storage compartment of
each of the trays.
Inventors: |
Waldrop; Christopher N.;
(Houston, TX) ; Waldrop; Michael W.; (Houston,
TX) ; Waldrop; David R.; (La Marque, TX) |
Family ID: |
45437560 |
Appl. No.: |
13/178611 |
Filed: |
July 8, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61363017 |
Jul 9, 2010 |
|
|
|
Current U.S.
Class: |
53/473 ; 53/167;
53/244 |
Current CPC
Class: |
B65B 61/20 20130101;
B65B 5/04 20130101; B65B 25/065 20130101; B65B 43/44 20130101 |
Class at
Publication: |
53/473 ; 53/244;
53/167 |
International
Class: |
B65B 5/00 20060101
B65B005/00 |
Claims
1. A packaging system for packaging food on a plurality of trays,
the packaging system comprising: a main conveyor configured to move
each of the plurality of trays about the packaging system; a tray
unloader for unloading one tray from a tray stack onto the main
conveyor; a food loader configured to place the food into each of
the trays; and a food accessory loader configured to place a food
accessory into a storage compartment of each of the trays.
2. The packaging system of claim 1, wherein the tray unloader
further comprises at least one tray engager configured to engage
the tray at an end of the tray.
3. The packaging system of claim 2, further comprising a drive
system configured to move the tray engager and thereby drop the
lowermost tray from the tray stack.
4. The packaging system of claim 3, wherein the at least one tray
engager has a curved shoulder and end configured to mirror the
contours of the ends of the tray.
5. The packaging system of claim 4, wherein the at least one tray
engager further comprises two tray engagers one having a convex
shoulder and convex end and the other having a concave shoulder and
concave end.
6. The packaging system of claim 4, wherein the at least one tray
engager further comprises two tray engagers one having a convex
shoulder and convex end and the other having a concave end with a
straight shoulder.
7. The packaging system of claim 2, wherein the tray engagers are
interchangeable in order to mirror the contours of the types of
packaging trays used in the packaging system.
8. The packaging system of claim 1, wherein the food accessory is a
thermometer.
9. A system for unloading a tray onto a main conveyor in a food
packaging facility, the system comprising: a stack conveyor
configured to convey a tray stack toward a tray feed area; a tray
unloader located proximate the tray feed area and configured to
remove a lowermost tray of the tray stack and place the tray onto
the main conveyor wherein the tray unloader comprises: a tray
engager for engaging an removing the lowermost tray; a drive system
configured to move the tray engager; and wherein each of the trays
has a tray bottom wherein the tray bottom is substantially flat and
has two substantially straight sides on opposite sides of a
perimeter of the tray bottom and two curved ends wherein a first
end is curved away from the tray bottom and a second end is curved
into the tray bottom and two side walls each extending above the
straight sides of the tray bottom and located on opposite sides of
the tray bottom and two curved end walls each extending above the
curved ends of the tray bottom and wherein each end of each of the
end walls is coupled to an end of the side wall thereby forming
walls extending from the perimeter of the tray bottom;
10. The system of claim 9, wherein the each of the trays further
comprise a storage area for a food accessory and a food storage
area for storing a food.
11. The system of claim 9, wherein the at least one tray engager
has a curved shoulder and curved end configured to mirror the
contours of the curved ends of the tray.
12. The system of claim 9, wherein the at least one tray engager
further comprises two tray engagers one having a convex shoulder
and convex end and the other having a concave shoulder and concave
end.
13. The system of claim 9, wherein the at least one tray engager
further comprises two tray engagers one having a convex shoulder
and convex end and the other having a concave end with a straight
shoulder.
14. The system of claim 9, wherein the tray engagers are
interchangeable in order to mirror the contours of the types of
trays used in the packaging system.
15. A method of packaging food comprising: placing a tray stack
onto a stack conveyor; moving the tray stack toward a tray feed
area; dropping the tray stack into the tray feed area; engaging a
lowermost tray with a tray dispenser system; using the tray
dispenser system to lower the lowermost tray onto a main conveyor;
moving the tray toward a food loader and loading a food into the
tray; and moving the tray toward a food accessory loader and
loading the food accessory into a storage area on a border of the
tray.
16. The method of claim 15, wherein using the tray dispenser
further comprises: engaging the lowermost tray with a plurality of
tray engagers; rotating the tray engagers with a drive system and
thereby releasing the lowermost tray;
17. The method of claim 15, further comprising engaging a convex
end wall of the tray with a concave shoulder and concave end of the
of the tray engager.
18. The method of claim 17, further comprising engaging a concave
end wall of the tray with a convex shoulder and convex end of the
of the tray engager.
19. The method of claim 15, wherein moving the tray toward the tray
feed area further comprises moving the tray stack on a conveyor.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/363,017 filed Jul. 9, 2010 which is herein
incorporated by reference in its entirety.
BACKGROUND
[0002] Embodiments of the inventive subject matter generally relate
to field of storing and packaging food. More specifically,
embodiments of the inventive subject matter generally relate a tray
for storing meat. More specifically still, embodiments of the
inventive subject matter relate to the tray having a border around
the tray, the border may have a storage compartment. More
specifically, embodiments relate to a machine for manipulating the
tray.
[0003] Meats such as sausages may be packed in Styrofoam, or
plastic containers. The containers are typically rectangular shaped
and the meat is placed inside the container. A plastic film may
then be placed over the meat in the container, and/or around the
entire container. The inside of the container is a rectangular
shape and does not conform to the shape of the meat. Therefore, the
meat often slides to one side during the shipping and stocking of
the meat.
[0004] Despite the development of techniques for packaging meats,
there remains a need to provide advanced techniques for packaging
meats in containers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present embodiments may be better understood, and
numerous objects, features, and advantages made apparent to those
skilled in the art by referencing the accompanying drawings.
[0006] FIG. 1 depicts a diagram illustrating a perspective view of
a packaging tray having a storage space.
[0007] FIG. 2 depicts a diagram illustrating a top view of the
packaging tray.
[0008] FIGS. 3A and 3B depict diagrams illustrating a top view of a
portion of the packaging tray.
[0009] FIG. 4 depicts a diagram illustrating a side view of a
plurality of packaging trays being nested together.
[0010] FIG. 5 depicts a diagram illustrating a perspective view of
the packaging tray and a food item.
[0011] FIG. 6 depicts a diagram illustrating a schematic view of a
packaging system for de-nesting the packaging tray.
[0012] FIG. 7 depicts a schematic view of the tray dispenser system
according to one embodiment.
[0013] FIG. 8A depicts a top view of the packaging tray engaged
with the tray dispenser.
[0014] FIG. 8B depicts a cross-sectional side view of the packaging
tray with the tray dispenser.
[0015] FIG. 8C depicts a cross-sectional side view of the packaging
tray with an alternate tray dispenser.
[0016] FIG. 9A depicts a top view of the packaging tray engaged
with an alternate tray dispenser.
[0017] FIG. 9B depicts a cross-sectional side view of the packaging
tray with the alternate tray dispenser.
[0018] FIG. 10 depicts a flow chart depicting a method for using
the packaging tray.
DESCRIPTION OF EMBODIMENT(S)
[0019] The present embodiments may be better understood, and
numerous objects, features, and advantages made apparent to those
skilled in the art by referencing the accompanying drawings. These
drawings are used to illustrate only typical embodiments of this
invention, and are not to be considered limiting of its scope, as
the invention may admit to other equally effective embodiments. The
figures are not necessarily to scale and certain features and
certain views of the figures may be shown exaggerated in scale or
in schematic in the interest of clarity and conciseness.
[0020] FIG. 1 depicts a packaging tray 100 for storing food. The
packaging tray 100 may have a food storage area 102 and a storage
compartment 104 for storing one or more food accessories 106. The
food storage area 102 as shown is configured to store food, for
example a plurality of sausages. Further, the food may be any
suitable food for storing in the packaging tray 100 including, but
not limited to, chicken beef, pork, fish, vegetables, fruits, and
the like. The food storage area 102 may be shaped to match the
typical contour of the food. Having the food storage area 102
shaped may minimize the material needed in the packaging thereby
reducing storage space and transportation costs associated with
packaging and shipping foods. In one embodiment, the food storage
area 102 may be curved at each end 108 in order to match the
contour of the sausage, or the food, and thereby minimize space
required for storage. Although the food storage area 102 is shown
as having a curved shape at the ends 108, it may have any shape
suitable for matching the contour of the food stored such as
square, rectangular, circular and the like.
[0021] The food storage area 102 of the packaging tray 100 may have
a plurality of walls 110 which surround the food storage area 102.
The walls 110 as shown have two side walls 112 and two end walls
114. The two side walls 112, as shown, are substantially parallel
to one another and have a length that is longer than the end walls
114.
[0022] The end walls 114a and 114b, as shown, may be curved. The
curve of end walls 114a and 114b may curve in the same direction
relative to the packaging tray 100. For example, as shown in FIG.
1, one of the end walls 114b curves, or extends, away from the food
storage area 102 while the other end wall 114a curves, or extends,
into the food storage area 102. The curved walls, as shown, may
have any suitable curvature. In one embodiment, the curvature of
the end walls 114a and 114b are configured to match the curvature
of sausages, for example Italian sausages, bratwurst, and the like.
Although the end walls 114a and 114b are shown as being curved in
the same direction, each of the end walls may be curved in opposite
directions. Further, the end walls 114a and/or 114b may be angled
rather than curved.
[0023] The walls 110 may have any suitable depth for containing the
food within the food storage area 102. The depth may be a distance
normal to the plane of a tray bottom 116, between bottom of the
wall 110 located near the tray bottom 116 of the packaging tray 110
to a top of the wall 110. As shown in FIG. 1 each of the walls 110
have substantially the same depth. Although, the walls 110 are
shown as having the same depth, the walls 110 may have varying
depths depending on the type of food to be stored in the packaging
tray 100. In one embodiment, the walls 110 may have a depth
configured to be slightly larger than a depth of the food to be
placed in the packaging tray 100. In this embodiment, the food
would be surrounded on three sides with the packaging tray 100,
while the fourth side or top may be covered with any suitable
covering to cover the food including, but not limited to a plastic
covering, a cardboard covering, and the like.
[0024] The walls 110 may be angled relative to the tray bottom 116.
For example, the walls 110 may have a slightly offset angle from a
plane perpendicular to the tray bottom 116, as shown in FIG. 1. The
angled walls 110 may allow multiple packaging trays 100 to be
stacked on top of one another in a space saving manner. Due to the
angle of the walls 110 tray bottoms 116 may be proximate one
another when empty packaging trays 100 are stacked on top of one
another. Although the walls 110 are shown as being angled, it
should be appreciated that the walls 110 may be perpendicular to
the tray bottom 116.
[0025] The tray bottom 116 may be a substantially planar member
coupled to the bottom of each of the walls 110. The tray bottom 116
may have a similar perimeter shape to the shape of the interior of
the walls 110. As shown, the tray bottom 116 has two parallel
straight ends coupled to the side walls 112 and two curved ends
coupled to the end walls 114. The tray bottom 116 may be integrally
formed with each of the walls 110, or selectively to one or more of
the walls 110. Further, the tray bottom 116 may be a formed
separately from the walls 110 and coupled thereto by any suitable
method including, but not limited to, gluing, stitching, melting,
and the like.
[0026] A border 118 may surround the walls 110 of the food storage
area 102. The border 118 may extend from the top of the walls 110
away from the food storage area 102. The border 118 may therefore
form a lip that extends from the walls 110 around the packaging
tray 100. As shown in FIG. 1, the border 118 may be substantially
parallel to the tray bottom 116. Although the border 118 is shown
as being substantially parallel to the tray bottom 116, it should
be appreciated that the border 118 may be angled relative to the
tray bottom 116. The border 118, as shown, extends out a thickness
t along the sides walls 112. The border 118 may extend a similar
thickness t along the curved wall 114b that curves away from the
food storage area 102. The border 118 along the other curved wall
114a that extends into the food storage area 102 may not match the
shape of the curved wall and thereby form a storage border 120.
[0027] The storage border 120 may have a varying thickness t along
the length of the storage border 120. The varying thickness may
allow a terminal end 122 of the storage border 120 to be
substantially linear. The terminal end 122 of the storage border
120 may be perpendicular to the side walls 110 as shown. The
perpendicular terminal end 122 of the storage border 120 may assist
one or more packaging machines in handling the packaging tray 100
as will be discussed in more detail below.
[0028] Due to the curved bottom end of the packaging tray 100, the
storage border 120 located in the border 118 has an extra width W
that may be used to provide the storage compartment 104. This
allows the packaging tray 100 to have the storage compartment 104
without substantially increasing the overall perimeter of the
border 118 and thereby the packaging tray 100. Although the storage
compartment 104 is shown as being located on top of the border 118
it may be at any suitable location such as the bottom of the border
118, the tray bottom 116, the bottom of the packaging tray 100, the
walls 110 of the food storage area 102, and the like.
[0029] FIG. 2 is a top view of the packaging tray 100 having the
storage border 120 with the storage compartment 104. The storage
compartment 104 may be configured and/or shaped to store any number
of the food accessories 106. As shown in FIG. 2, the storage
compartment 104 has the shape of a thermometer 200, or "done
stick." The storage compartment 104 may have a depth configured to
store one and/or multiple thermometers 200.
[0030] FIG. 3A is a top view of a portion of the packaging tray 100
showing the storage compartment 104 having the thermometer 200 as
the food accessory 106. The one or more thermometers 200 may be a
disposable thermometer used to test the temperature of the food
while cooking. As shown, the thermometer 200 may have a tip 300, a
handle 302, and an indicator 304. The tip 300 may be configured to
be placed in, and/or onto the food while cooking the food. As
shown, the tip 300 has a pointed, or angled portion 306 configured
to pierce the food. The handle 302 as shown is a wider flat portion
that is configured to be gripped by a person when inserting and/or
removing the thermometer 200 from the food. Although the tip 300 is
shown as an angled portion 306, the tip 300 may be any suitable
shape and/or surface for measuring the temperature of the food.
Further, the handle 302 may be any suitable shape for gripping the
thermometer 200. Although the thermometer 200 is shown as a flat
thermometer having a tip for piercing the food, the thermometer 200
may be any suitable thermometer for placing in the storage
compartment including, but not limited to, a flat thermometer for
placing flat on the food, a standard mercury thermometer, a digital
thermometer, and the like.
[0031] The indicator 304 as shown has a visual indicator 308 and a
temperature indication 310. The visual indicator 308 may simply
change colors when the tip 300 reaches a desired temperature, or
give another visual alert. The visual indicator 308 as shown
displays the temperature at which the food in the packaging tray
100 is cooked, or done. It should be appreciated that the indicator
304 may take any suitable form so long as the thermometer 200
indicates the temperature of the food, and/or when the food will
reach a certain temperature. The thermometer 200 may be
specifically designed for the food being prepared. For example, the
cook temperatures for poultry may be higher than in red meat. Thus,
for a poultry food item the thermometer 200 may have an indicator
that alerts the cook that the poultry has reached the poultry cook
temperature, or done temperature.
[0032] Although the storage compartment 104 and the food accessory
106 are described for storing the thermometer 200, it should be
appreciated that they may be used for storing any food accessory
such as, a condiment (for example ketchup, mustard, BBQ sauce,
salt, pepper, spices, soy sauce, wasabi, and the like), a plastic
storage bag, one or more chop sticks, a fork, and/or a tong, and
the like.
[0033] FIG. 3B is a top view of a portion of the packaging tray 100
showing two of the storage compartments 104 having two separate
food accessories 106. This may allow multiple food accessories 106
to be packaged as a set with the food and the packaging tray 100.
Any of the food accessories may be used in combination to enhance
the set of the packaging tray 100, for example, the food
accessories 106 may include, but are not limited to, the
thermometer 200 and a condiment, a fork and a knife, soy sauce and
wasabi, and the like. Although there are only two storage
compartments 104 shown with two food accessories 106, it should be
appreciated that there may be any suitable number of storage
compartments 104 having any suitable number of food accessories
106.
[0034] FIG. 4 depicts a side view of two of the packaging trays 100
ready to be stacked on top of one another. As shown, the walls 110
are sloped toward the center of the packaging tray 100. The slope
of the walls 110 may allow empty packaging trays 100 to be stacked
on top of one another thereby allowing the tray bottom 116 and the
borders 118 of each of the packaging trays 100 to be proximate one
another, or nested together. This nested arrangement allows a
larger number of packaging trays 100 to be stacked on top of one
another for shipping and storage.
[0035] FIG. 5 depicts a perspective view of the packaging tray 100
with the food accessory 106 (as shown in FIGS. 1-3B) removed from
the storage compartment 104. In FIG. 5, the food 500 is a sausage
and the food accessory 106 is the thermometer 200. The thermometer
200 may be placed in the food 500 during cooking of the food, as
described above. The empty storage compartment 104, as shown, is
contoured to the shape of the thermometer 200. By making the
storage compartment 104 a similar shape as the thermometer 200
and/or the food accessory 106, the food accessory 106 may be
prevented from moving and/or shifting during transport of the
packaging tray 100. Although, the storage compartment 104 is shown
to be shaped the same as the thermometer 100, it should be
appreciated that the storage compartment 104 may be shaped to fit
the contour of any suitable food accessory including, but not
limited to, any of the food accessories 106 described herein.
Further, the storage compartment 104 may have any suitable shape
for holding one or more food accessories.
[0036] The packaging tray 100 as shown in FIGS. 1-5 may be made of
any suitable material including, but not limited to, Styrofoam,
plastic, cardboard, foam, aluminum, and the like.
[0037] The packaging tray 100 may further have one or more
partitions (not shown) located in the food storage area 102. The
partitions may be configured to keep portions of the food 500
separated. For example, if the food 500 is sausage, there may be a
partition between each of the sausages in the packaging tray.
[0038] FIG. 6 depicts a portion of a packaging system 600 for
packing each of the packaging trays 100 with the food 500 and/or
the food accessories 106. The packaging system 600 may be located
at a packing facility, for example a meat packing facility. The
packaging trays 100 may be shipped to the packing facility empty
and in one or more tray stacks 602. The tray stacks 602 may reduce
the shipping size required to ship the packaging trays 100.
Further, the concave and convex shape of the end walls 114 of the
packaging tray 100 may reduce wasted space in the packaging trays
100 by having the packaging trays conform to the shape of the food
500. The reduction in wasted space and shipping size may increase
the number of packaging trays 100 that may be shipped in a truck,
railcar, and/or container thereby reducing transportation
costs.
[0039] The packaging system 600 may have a tray unloader 604, a
main conveyer 606, a food loader 608 and a food accessory loader
610. The packaging system 600 may be configured to separate the
tray stacks 602 into individual trays, then load the food storage
area 102 with the food 500, and seal the packaging tray 100 for
shipping to a retailer (not shown). Optionally, the packaging
system 600 may load the food accessory 106 onto the packaging tray
100.
[0040] The tray stacks 602, or portions thereof, may be placed on
the tray unloader 604 portion of the packaging system. The tray
unloader 604 may have a stack conveyer 612, a tray feed area 614,
and a tray dispenser system 616. The tray dispenser system 616 may
be configured to place one or the packaging trays 100 on the main
conveyer 606 individually. The tray unloader 604 as shown is
located above the main conveyer 606 thereby allowing the individual
packaging trays 100 to be dropped onto the main conveyer 606. The
tray unloader 604 may be a stand-alone unit that may be moved to a
location proximate the main conveyor 606, or may be connected to
and fixed to the main conveyor 606. Although the tray unloader 604
is shown as being located above the main conveyor 606, it should be
appreciated that the tray conveyor 606 may be located at any
suitable location for delivering the individual packaging trays 100
onto the main conveyor 606 including, but not limited to, next to
the main conveyor 606.
[0041] The stack conveyor 612 may move the tray stacks 602 toward
the tray feed area 614 to be delivered onto the main conveyor 606.
As shown, the stack conveyor 612 is has a conveyor belt 618 that
the tray stacks 602 rest on. The conveyor belt 618 may be powered
by any suitable drive system (not shown) including, but not limited
to, an electric motor, a pneumatic system, a hydraulic system, a
combustion engine and the like. The conveyor belt 618 may move the
tray stacks 602, at a constant rate in accordance with the rate
each of the tray stacks 602 are fed onto the main conveyor 606.
Further, the conveyor belt 618 may move, only when the tray feed
area 614 is ready to accept a new tray stack 602. Any number of
sensors and/or operator input may be used to signal to the drive
system when to activate the stack conveyor 612. Although the stack
conveyor 612 is shown as a conveyor belt 618, it should be
appreciated that any suitable conveyor system may be used to move
the tray stacks 602 into the feed area including, but not limited
to, a pneumatic conveyor system, a hydraulic conveyor system, a
gravity roller conveyor, gravity skate wheel conveyors, wire mesh
conveyors, plastic belt conveyors, and the like.
[0042] The feed area 614 as shown is an open area 620 surrounded by
one or more guide walls 622. The guide walls 622 guide the
packaging trays 100 to the tray dispenser system 616. The guide
walls 622 may be any suitable wall and/or surface for restricting
the travel of the packaging trays 100 toward the tray dispenser
system 616. As shown, there are two guide walls 622 although there
may be any suitable number of guide walls 622 including, but not
limited to, three guide walls 622 and four guide walls 622, so long
as the guide walls 622 guide the packaging trays 100 to the tray
dispenser system 616.
[0043] The tray dispenser system 616 may be configured to remove
one of the packaging trays 100 from the tray stack 602 and deliver
the packaging tray 100 onto the main conveyer 606. The tray
dispenser system 616 may remove one of the packaging trays 100 from
the tray stack 602 while preventing the remaining packaging trays
100 from moving onto the main conveyor 606, as will be discussed in
more detail below.
[0044] The main conveyor 606 may move the individual packaging
trays 100 through the packaging system 600. The main conveyor 606
as shown is a conveyor belt 618 for moving the packaging trays 100.
The conveyor belt 618 may have any suitable drive system including,
but not limited to, those described herein. Although the main
conveyor 606 is shown as a conveyor belt 618, the main conveyor 606
may be any suitable conveyor system including, but not limited to,
those described herein. The main conveyor 606 may have one or more
dividers 624 for separating the packaging trays 100.
[0045] The main conveyor 606 may move the each of the empty
individual packaging trays 100 to the food loader 608 (shown
schematically). The food loader 608 may place the food 500 in each
of the packaging trays 100. In the event the food 500 is one or
more sausages, the food loader 608 may place the sausages in the
packaging tray 100 in a manner that the natural curve of the
sausages matches the curve of the end walls 114 of the packaging
trays 100. The food loader 608 may be any suitable system and/or
device for loading the food 500 on the packaging trays 100
including, but not limited to, one or more robotic arms, a worker,
a feed system, and the like.
[0046] The food accessory loader 610 (shown schematically) may
place the food accessory 106 into the storage compartment 104 of
the packaging tray 100. The food accessory loader 610, as shown, is
located downstream of the food loader 608 thereby placing the food
accessory 106 in the packaging tray 100 after the food 500 is in
the packaging tray 100. It should be appreciated that the food
accessory loader 610 may be located upstream of the food loader
608. The food accessory loader 610 may be any suitable system
and/or device for loading the food accessory 106 into the storage
compartment 104 including, but not limited to, one or more robotic
arms, a worker, a feed system, and the like.
[0047] FIG. 7 depicts a schematic view of the tray dispenser system
616, according to one embodiment. The tray dispenser system 616 may
have one or more tray engagers 700 and a tray dispenser drive
system 702 (shown schematically). The tray engagers 700 may be
configured to engage one of the packaging trays 100 and move the
packaging tray 100, and/or drop the packaging tray 100, onto the
main conveyor 606. The tray dispenser drive system 702 may be
configured to move the one or more tray engagers 700. The tray
dispenser system 616 needs to engage and separate the packaging
trays 100 without damaging the packaging trays 100.
[0048] The tray engagers 700, as shown, in FIG. 7 are arms 704
configured to engage the end walls 114, and/or the border 118
proximate the end walls 114, of the packaging tray 100. Because the
end walls 114 of the packaging tray 100 are curved, the arms 704
may have a matching curved portion. As shown, the arm 704 engaging
the packaging tray 100 near the end wall 114A curved into the food
storage area 102 may have a convex engagement surface 706. The
convex engagement surface 706 may be curved to mirror the curvature
of the end wall 114A. The arm 704 engaging the packaging tray 100
near the end wall 114B curved away for the food storage area 102
may have a concave engagement surface 708. The concave engagement
surface 708 may be curved to mirror the curvature of the end wall
114B.
[0049] Due to the curvature of the end walls 114A and 114B, a
straight surface on the tray engagers 700 may decrease the amount
of surface contact between the tray engager 700 and the packaging
tray 100. The decreased surface contact may cause the packaging
tray 100, and/or multiple packaging trays 100, to fall, or dislodge
prematurely from the tray dispenser 616. The falling packaging
trays 100 may cause a stoppage, or slow down, in the packaging
operation. The stoppage may cause the meat packing facility to lose
money due to lost production. The convex engagement surface 706 and
the concave engagement surface 708 may greatly increase the surface
contact between the tray dispenser 616 and the packaging tray 100.
The increased surface contact may further reduce stress at the
contact point between the tray dispenser system 616 and the
packaging tray 100.
[0050] FIGS. 8A and 8B depict a top view and a cross-sectional side
view of the packaging tray 100 engaged with the tray dispenser 616.
The convex engagement surface 706 and the concave engagement
surface 708 of the tray engagers 700, as shown, may have a shelf
800 configured to engage a bottom surface of the border 118
proximate each of the end walls 114A and 114B respectively. The
shelf 800 may have a flat top 802 for supporting the border 118 and
a concave and/or convex curved end 804A and 804B for mirroring the
curvature of the end walls 114A and 114B respectively. The flat top
802 may support the packaging tray 100 from the bottom of the
border 118. The concave and/or convex curved ends 804A and 804B may
be configured to engage the outer surface of the end walls 114A and
114B, or leave a small gap therebetween.
[0051] The tray engagers 700 may further have a shoulder 806A and
806B. The shoulders 806A and 806B may engage an edge of the border
118 when the packaging tray 100 is supported by the tray engagers
700. The shoulders 806A and 806B may be curved to match the
curvature of the border 118. For example, the shoulder 806A may be
convex, or extend outwardly, to mirror the inwardly curved the wall
114A and the shoulder 806B may be concave, or curve inwardly, to
mirror the outwardly curved the wall 114B. The shoulders 806A and
806B are shown as being perpendicular to the edge of the border 118
although it should be appreciated that the shoulders 806A and 806B
may have any suitable angle relative to the edge of the border
118.
[0052] Although the tray engagers 700 are shown as having the
convex and concave shoulders 806A and 806B, curved ends 804A and
804B it should be appreciated that one of the shoulders 806 may be
straight to match the edge of the packaging tray 100 as shown in
FIG. 1.
[0053] When the tray stack 602 enters the tray feed area 614 (as
shown in FIG. 6) the lowermost packaging tray 100 may engage the
tray engagers 700 of the tray dispenser 616. In FIGS. 7 and 8A and
8B, the tray engagers 700 are shown in a support position wherein
the packaging tray 100 is supported by the tray engagers 700. In
the support position, the flat top 802 on each of the tray engagers
700 may support the packaging tray 100 by engaging the bottom of
the border 118, and/or any suitable location on the packaging tray
100. The tray engagers 700 may remain in the support position until
the packaging tray 100 is to be placed on the main conveyor
606.
[0054] To move the packaging tray 100 onto the main conveyor 606, a
support may prevent support the packaging trays 100 in the tray
stack 602, with the exception of the lowermost packaging tray 100.
The tray engagers 700 may then be rotated toward a release position
by the drive system 702 as shown in FIG. 7. The rotation toward the
release position is indicated by arrows 710 on FIGS. 7 and 8B. As
the tray engagers 700 rotate toward the release position, the lower
most packaging tray 100 slides off of the tray dispenser 616 and is
placed on the main conveyor 606. The drive system 702 may then move
the tray engagers 700 back to the support position to receive the
next packaging tray 100.
[0055] In an embodiment, a secondary tray engager 750 (as shown in
FIG. 7) may be used to catch the packaging tray 100 when it is
released from the tray engager 700. As shown, the secondary tray
engager 750 is a substantially cylindrical member 752 having the
shelf 800 and a shoulder 752. As the tray engager 750 releases the
lowermost packaging tray 100, the shoulder 806 of the secondary
tray engager 750 may catch the lowermost tray 100. The tray engager
700 may then reengage the second to last packaging tray in the tray
stack 602. A motor 712 may then rotate secondary tray engager 750
in order to mover the shelf 802 clear of the packaging tray 100 and
allowing the shoulder 752 to optionally push the packaging tray 100
onto the conveyor 618. Any of the tray dispensers 616 may include
the secondary tray engager 750.
[0056] The drive system 702 (as shown in FIG. 7) may be any
suitable drive system for moving and/or rotating the tray dispenser
616 and/or the secondary tray engager 750. In one embodiment, the
drive system 702 may have a motor 712, or motive device, configured
to rotate a drive shaft 714. The drive shaft 714 may couple to
and/or be integral with the tray engagers 700 of the tray dispenser
616. The motor 712 may be any suitable motor for motivating the
tray dispenser 616 including, but not limited to, an electric
motor, a pneumatic motor, a hydraulic motor, a combustion engine,
and the like. The drive system 702 may have any suitable devices
and/or systems to assist in the motivation and control of the tray
dispensers 616 including, but not limited to, controllers, servos,
pulleys, chain drives, drive shafts and the like.
[0057] FIG. 8C depicts a cross-sectional view of another embodiment
of the tray engagers 700. As shown, the tray engager 700 may pivot
about a location located above the lowermost packaging tray 100 of
the tray stack. The tray engagers 700 may form an L-shaped member
having the shelf 800 and the shoulder 806. The shelf 800 and/or the
shoulder 806 may be convex, concave and/or straight in a similar
manner as any of the tray engagers 700 described herein.
[0058] The tray dispensers 616 may be specifically designed to be
removable and replaceable in order to customize the packing system
600 to the type of packaging tray being used. The tray dispensers
616 may be uncoupled from the drive system 702 and replaced with an
alternate tray dispenser when the type of packaging tray is changed
in the packing system 600. For example, the packaging tray 100B (as
shown in FIGS. 8A and 8B) having two curved end walls 114 may be
replaced by the packaging tray 100A having a straight border 118 on
the curved end wall 114A. The tray engager 700A may then be
replaced by a tray engager 700A having the convex curved ends 804A
on the shelf 800 and a straight shoulder 806A thereby mirroring the
configuration of the packaging tray 100A. The packaging system 600
may then use square trays (not shown). The tray engages 700A and
700B may then be replaced again by replacing the tray engagers 700A
and 700B having straight ends (not shown) on the shelf 800 and
straight shoulders (not shown). Although the tray dispenser 616 is
described as being replaceable, it should be appreciated that the
tray dispenser 616 may be replaced along with a portion of the
drive system 702. For example, the drive shaft 714 and the tray
dispensers 616 may form a unit that can be quickly removed and
replaced.
[0059] FIGS. 9A and 9B show an alternative embodiment of the tray
dispensers 616. As shown, the tray dispenser 616 is two shaft tray
engagers 900A and 900B. The shaft tray engagers 900A and 900B may
be drive shafts that have a curvature that mirrors the curvature of
the border 118 of the packaging tray 100B. Each of the shaft tray
engagers 900A and 900B may have the shelf 800 and the shoulder 806A
and 806B as described above. As shown in FIGS. 9A and 9B, the tray
dispenser 616 is in the support position. The drive system 702 may
rotate the shaft tray engagers 900A and 900B toward the release
position as indicated by arrows 710 in a similar manner as
described above. As the shaft tray engagers 900A and 900B rotate to
the release position, the packaging tray 100B may be released.
Further, the outer perimeter 902 of the shaft tray engagers 900A
and 900B (as shown in FIG. 9B) may engage and support the next
packaging tray 100B in the tray stack 602 (as shown in FIG. 6). The
shaft tray engagers 900A and 900B may be removed and replaced in
any suitable manner including those described herein.
[0060] FIG. 10 depicts flow chart of a method of providing a food
package to a consumer. The flow begins at block 1000 wherein a
packaging tray is provided. The packaging tray may be any suitable
packaging tray including, but not limitd to those described herein.
The flow continues at block 1002, wherein a food is placed in a
food storage area of the packaging tray 1002. The food may be any
suitable food including those described herein. The flow continues
at block 1004, wherein a food accessory is placed in a storage
compartment on a border of the packaging tray. The flow continues
at block 1006, wherein the packaging tray is wrapped in a manner
that displays the food and the food accessory to a customer. The
wrapping may be any suitable wrapping such as plastic, polymer,
cardboard, paper, a combination thereof and the like.
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