U.S. patent application number 15/373835 was filed with the patent office on 2018-06-14 for packing tray for stack of hollow conical objects.
The applicant listed for this patent is Tekni-Plex, Inc.. Invention is credited to Mark A. Bergeron, Babu Kuruvilla.
Application Number | 20180162624 15/373835 |
Document ID | / |
Family ID | 62488343 |
Filed Date | 2018-06-14 |
United States Patent
Application |
20180162624 |
Kind Code |
A1 |
Bergeron; Mark A. ; et
al. |
June 14, 2018 |
PACKING TRAY FOR STACK OF HOLLOW CONICAL OBJECTS
Abstract
Packing tray for protecting fragile hollow conical objects, such
as conical ice cream cones, which allows a stack of such conical
objects to be held securely in a pocket of the packing tray, and
which allows a plurality of stacked trays and objects to be
packaged in cartons. The packing tray is a plastic foam sheet
having a top wall and one or more recessed elongated pockets
extending downwardly from the top wall, each pocket holding a stack
of conical objects. Each pocket includes a floating bottom and
flexible and fluted sidewall pleats for dissipating exterior
applied forces and snugly engaging a stack of cones held in the
pocket, thereby improving product protection, in a relatively low
cost and lighter weight construction.
Inventors: |
Bergeron; Mark A.; (Monroe,
GA) ; Kuruvilla; Babu; (Griffin, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tekni-Plex, Inc. |
Wayne |
PA |
US |
|
|
Family ID: |
62488343 |
Appl. No.: |
15/373835 |
Filed: |
December 9, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 2585/363 20130101;
B65D 85/36 20130101; B65D 43/02 20130101; B65D 81/025 20130101;
B65D 81/05 20130101; B65D 2581/055 20130101; B65D 43/16 20130101;
B65D 21/0212 20130101 |
International
Class: |
B65D 81/05 20060101
B65D081/05; B65D 43/16 20060101 B65D043/16; B65D 43/02 20060101
B65D043/02; B65D 21/02 20060101 B65D021/02; B65D 85/36 20060101
B65D085/36 |
Claims
1. A packing tray for conical ice cream cones and other hollow
conical objects, the packing tray comprising: a plastic foam sheet
having a top wall surrounding one or more recessed elongated
pockets, the top wall defining a top reference plane (TRP) and the
pockets extending downwardly from the TRP; each pocket having an
elongated axis parallel to the TRP and being configured to hold a
stack of nested conical objects between opposing elongated
sidewalls, first and second end walls, and a bottom wall; each
pocket further including: a) a conical portion adjacent the first
end wall to accommodate an outer conical object of the stack, the
conical portion including an upwardly angled wall, at an acute
angle to the TRP, disposed between the bottom wall and the first
end wall; and b) a rectilinear portion including the bottom wall
and disposed adjacent the second end wall to accommodate the
remainder of the stack; a bottom floating pad disposed in the
rectilinear portion above the bottom wall, the bottom floating pad
comprising a bottom platform disposed upwardly of the bottom wall
and joined to the bottom wall by a plurality of expandable flutes;
an angled floating pad disposed in the conical portion above the
angled wall, the angled floating pad comprising an angled platform
disposed upwardly of the angled wall and joined to the angled wall
by a plurality of expandable flutes, wherein a gap is defined
between the angled floating pad and bottom floating pad to allow a
top open end lip of the outer conical object of the stack to hang
freely in the gap between the angled wall and the bottom wall; and
wherein the expandable flutes flex in response to the weight and
dimensions of the stack of conical objects enabling the bottom
platform to move with respect to the bottom wall and the angled
platform to move with respect to the angled wall.
2. The packing tray of claim 1, wherein the sidewalls have
expandable flutes to accommodate movement of the sidewalls with
respect to the bottom wall.
3. The packing tray of claim 1, wherein a second gap is defined
between the first end wall and the angled floating pad to allow a
conical tip end of the outer conical object of the stack to hang
freely in the second gap between the angled floating pad and the
first end wall.
4. The packing tray of claim 1, wherein the first end wall has a
conical shape configured to engage a conical tip end of the outer
conical object of the stack.
5. The packing tray of claim 1, wherein one or more bumpers extend
into the pocket from the second end wall to space the open top lip
end of the innermost conical object from the second end wall.
6. The packing tray of claim 1, wherein the second end wall is
disposed at an acute angle to the TRP.
7. The packing tray of claim 1, wherein each pocket has a
downwardly extending foot support surrounding the bottom wall and
angled wall.
8. The packing tray of claim 7, wherein the foot support comprises
a bottom perimeter of the pocket.
9. A pair of first and second packing trays according to claim 8,
disposed in a vertically stacked arrangement, wherein the foot
support of the first packing tray engages the foot support of the
second packing tray.
10. The packing tray of claim 1, wherein the peripheral surface
includes a planar trim lip around the perimeter of the top
wall.
11. A pair of first and second packing trays according to claim 10,
disposed in a vertically stacked arrangement, wherein the trim lip
of the first packing tray engages the trim lip of the second
packing tray.
12. The packing tray of claim 1, wherein the tray includes a
plurality of elongated pockets in a side-by-side arrangement with
their elongated axes in parallel.
13. The packing tray of claim 1, wherein the top wall has a
substantially rectangular perimeter and the tray has a plurality of
elongated pockets in a side-by-side arrangement with their
elongated axes in parallel.
14. The packing tray of claim 1, wherein the tray is unitarily
formed from a single foam sheet.
15. The packing tray of claim 1, wherein the plastic foam sheet
comprises one or more of polystyrene, polyester, polyolefin,
polypropylene, and poly(lactic acid), including homopolymers,
co-polymers and mixtures thereof, and including virgin and
reclaimed materials.
16. The packing tray of claim 15, wherein the plastic sheet
comprises polystyrene foam.
17. The packing tray of claim 1, wherein each pocket has a pocket
depth, between the bottom wall and top wall, configured to be about
half of a diameter of an open top end lip of an outer conical
object of the stack.
18. A stack comprising: a set of two packing trays of claim 1
stacked with an upper surface of their top walls in facing
engagement with one another; wherein the elongated pockets of the
two trays are configured to form a combined pocket space that
engages a perimeter of the stack of conical objects.
19. The stack of one or more sets of packing trays of claim 18,
disposed in a box for storage, shipment or display.
20. The stack of claim 18, comprising multiple sets of packing
trays, wherein each pocket has a downwardly extending foot support
surrounding the bottom wall and angled wall, and adjacent sets are
stacked with their foot supports in facing engagement with one
another.
21. A method of packing conical ice cream cones or other conical
objects in a stack comprising: forming a stack by positioning two
packing trays of claim 1 stacked with an upper surface of their top
walls in facing engagement with one another; wherein the elongated
pockets of the two trays are configured to form a combined pocket
space that engages a perimeter of the stack of conical objects.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a plastic packing tray for
holding fragile hollow conical objects, such as ice cream cones,
and adapted for stacking multiple such filled trays in a
carton.
BACKGROUND OF THE INVENTION
[0002] Packing trays having recessed pockets are commonly used to
package fragile objects to enable their safe storage, transport
and/or display. For example, fragile items such as ice cream cones
are typically arranged in a stack disposed in an elongated pocket
of a base tray. A second tray, or hinged tray top, may be applied
over the base tray, and then multiple such filled trays packaged in
a container (such as a carton or box) for shipment. Alternatively,
a single tray and cover may be packaged in a box for purchase by an
individual consumer. In either case, transport from a manufacturer
to a retail outlet, or transport from a retail outlet to the home
of an individual consumer, the transport poses significant risks of
breakage caused by, e.g., heavy objects being placed on top of the
carton, the carton being thrown or dropped, or the carton otherwise
encountering impact forces from any side that may crush the package
and the enclosed objects. In particular, ice cream cones are
relatively brittle and will crack if subject to even moderate
pressure. A broken cone is of little use to the consumer or food
retailer and is typically discarded.
[0003] Thus, there is a need for a packing tray that provides
sufficient protection from mechanical forces encountered during
packaging, shipment and/or storage so as to avoid damaging the
enclosed fragile objects, such as conical ice cream cones or other
hollow conical objects.
[0004] There is also a need to provide such a packing tray at a
lower cost and lighter tray weight to reduce the cost of shipment
and/or the cost of manufacturing the tray.
SUMMARY OF THE INVENTION
[0005] In accordance with one embodiment of the invention, a
packing tray is provided for protecting fragile hollow conical
objects, such as conical ice cream cones, which allows a stack of
such conical objects to be held securely in a pocket of the packing
tray, and which allows a plurality of stacked trays and objects to
be packaged in cartons.
[0006] The packing tray is a plastic foam sheet having a top wall
and one or more recessed elongated pockets extending downwardly
from the top wall, each pocket holding a stack of conical objects.
Each pocket includes a floating bottom and flexible and fluted
sidewall pleats for dissipating exterior applied forces and snugly
engaging a stack of cones held in the pocket, thereby improving
product protection, in a relatively low cost and lighter weight
construction. Typically, several stacks of cones are laid in
multiple row pockets and then another tray is flipped over and laid
on the bottom filled tray. In this manner, the elongated pockets of
the second flipped tray cushion and shield the upper edges of the
stack of cones lying above the top wall of the lower tray. A second
layer of cones can then be loaded in a third tray and covered with
a fourth flipped tray. The number of layers is determined by the
depth of the packing carton, wherein stacked layers of two to three
covered trays are typically stacked in a single shipping
carton.
[0007] The tray itself includes various features for protecting the
fragile cones. A floating bottom and fluted sidewalls help to
relieve stress on the cones, allowing each stack of cones to move
downwardly (transverse to the top wall of the tray) and outwardly
(parallel to the direction of the top wall), as pressures are
applied to the tray or carton. The fluted sidewalls also
accommodate for variations in cone diameters. The floating bottom
includes two separate floating bottom portions, a lowermost bottom
floating pad attached by expandable flutes to a bottom wall of the
pocket, and an angled floating pad, disposed between the bottom
floating pad and one end of the pocket, and at an acute angle to
the top wall, and similarly connected by expandable flutes to an
angled bottom wall of the pocket. The outermost cone of the stack
rests on the angled floating pad, and preferably voids are provided
adjacent each end of the angular floating pad to relieve pressure
at both ends (the conical tip and opposing open top end of the
outer cone) to prevent breakage thereof. In addition, two or more
end bumpers may be positioned, offset from the elongated centerline
of the pocket, for engaging the open top end of the innermost cone
in the stack, at the opposing end of the pocket (opposite the
angled floating pad). Still further, the tray may include a foot
support provided substantially around the entire perimeter of the
recessed pocket to act both as a support for stacking one flipped
tray on top of a lower base tray, and also to act as an additional
shock absorber. Still further, long trim flanges may be provided
all around the tray to minimize the shock or force transfer from
outside edges of the tray or carton to the stack of cones.
[0008] In accordance with one embodiment of the invention, a
packing tray for conical ice cream cones and other hollow conical
objects is provided, the packing tray comprising: [0009] a plastic
foam sheet having a top wall surrounding one or more recessed
elongated pockets, the top wall defining a top reference plane
(TRP) and the pockets extending downwardly from the TRP; [0010]
each pocket having an elongated axis parallel to the TRP and being
configured to hold a stack of nested conical objects between
opposing elongated sidewalls, first and second end walls, and a
bottom wall; [0011] each pocket further including: a) a conical
portion adjacent the first end wall to accommodate an outer conical
object of the stack, the conical portion including an upwardly
angled wall, at an acute angle to the TRP, disposed between the
bottom wall and the first end wall; and b) a rectilinear portion
including the bottom wall and disposed adjacent the second end wall
to accommodate the remainder of the stack; [0012] a bottom floating
pad disposed in the rectilinear portion above the bottom wall, the
bottom floating pad comprising a bottom platform disposed upwardly
of the bottom wall and joined to the bottom wall by a plurality of
expandable flutes; [0013] an angled floating pad disposed in the
conical portion above the angled wall, the angled floating pad
comprising an angled platform disposed upwardly of the angled wall
and joined to the angled wall by a plurality of expandable flutes,
wherein a gap is defined between the angled floating pad and bottom
floating pad to allow a top open end lip of the outer conical
object of the stack to hang freely in the gap between the angled
wall and the bottom wall; and [0014] wherein the expandable flutes
flex in response to the weight and dimensions of the stack of
conical objects enabling the bottom platform to move with respect
to the bottom wall and the angled platform to move with respect to
the angled wall is provided.
[0015] In one embodiment, the sidewalls have expandable flutes to
accommodate movement of the sidewalls with respect to the bottom
wall.
[0016] In one embodiment, a second gap is defined between the first
end wall and the angled floating pad to allow a conical tip end of
the outer conical object of the stack to hang freely in the second
gap between the angled floating pad and the first end wall.
[0017] In one embodiment, the first end wall has a conical shape
configured to engage a conical tip end of the outer conical object
of the stack.
[0018] In one embodiment, one or more bumpers extend into the
pocket from the second end wall to space the open top lip end of
the innermost conical object from the second end wall.
[0019] In one embodiment, the second end wall is disposed at an
acute angle to the TRP.
[0020] In one embodiment, each pocket has a downwardly extending
foot support surrounding the bottom wall and angled wall.
[0021] In one embodiment, the foot support comprises a bottom
perimeter of the pocket.
[0022] In one embodiment, a pair of first and second packing trays
is disposed in a vertically stacked arrangement, wherein the foot
support of the first packing tray engages the foot support of the
second packing tray.
[0023] In one embodiment, the peripheral surface includes a planar
trim lip around the perimeter of the top wall.
[0024] In one embodiment, a pair of first and second packing trays
is provided, disposed in a vertically stacked arrangement, wherein
the trim lip of the first packing tray engages the trim lip of the
second packing tray.
[0025] In one embodiment, the tray includes a plurality of
elongated pockets in a side-by-side arrangement with their
elongated axes in parallel.
[0026] In one embodiment, the top wall has a substantially
rectangular perimeter and the tray has a plurality of elongated
pockets in a side-by-side arrangement with their elongated axes in
parallel.
[0027] In one embodiment, the tray is unitarily formed from a
single foam sheet.
[0028] In one embodiment, the plastic foam sheet comprises one or
more of polystyrene, polyester, polyolefin, polypropylene, and
poly(lactic acid), including homopolymers, co-polymers and mixtures
thereof, and including virgin and reclaimed materials.
[0029] In one embodiment, the plastic sheet comprises polystyrene
foam.
[0030] In one embodiment, each pocket has a pocket depth, between
the bottom wall and top wall, configured to be about half of a
diameter of an open top end lip of an outer conical object of the
stack.
[0031] In another embodiment, a stack is provided comprising:
[0032] a set of two packing trays stacked with an upper surface of
their top walls in facing engagement with one another; [0033]
wherein the elongated pockets of the two trays are configured to
form a combined pocket space that engages a perimeter of the stack
of conical objects.
[0034] In one embodiment, a stack of one or more sets of packing
trays is provided, disposed in a box for storage, shipment or
display.
[0035] In one embodiment, the stack comprises multiple sets of
trays, wherein each pocket has a downwardly extending foot support
surrounding the bottom wall and angled wall, and adjacent sets are
stacked with their foot supports in facing engagement with one
another.
[0036] In one embodiment, a method of packing conical ice cream
cones or other conical objects in a stack is provided comprising:
[0037] forming a stack by positioning two packing trays stacked
with an upper surface of their top walls in facing engagement with
one another; [0038] wherein the elongated pockets of the two trays
are configured to form a combined pocket space that engages a
perimeter of the stack of conical objects.
[0039] These and other advantages of the present invention will be
apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] FIG. 1 is top perspective view of a packing tray having four
parallel elongated recessed pockets, each pocket for holding a
stack of hollow conical objects, such as conical ice cream cones,
according to one embodiment of the invention;
[0041] FIG. 2 is a top plan view of the tray of FIG. 1;
[0042] FIG. 3 is a side cross sectional view showing one pocket of
the tray of FIG. 1;
[0043] FIG. 4 is a cross sectional end view showing a transverse
view of the interior of four pockets of the tray of FIG. 1;
[0044] FIG. 5 is a top plan view, similar to FIG. 2, with a stack
of conical ice cream cones disposed in each elongated pocket of the
tray;
[0045] FIG. 6 is a side cross sectional view similar to FIG. 3, but
showing a sectional view of the stack of cones in the recessed
pocket;
[0046] FIG. 7 is a cross sectional end view similar to FIG. 4, but
showing a sectional view of the stack of cones in each pocket;
[0047] FIG. 8 is a top perspective view of multiple stacked trays
for positioning in a carton (as shown in FIG. 9);
[0048] FIG. 9 is a cross sectional view of the stacked trays of
FIG. 8 in a carton, showing (across each horizontal row) four
stacks of cones disposed in mating lower and upper recessed pockets
of a bottom tray and a top tray respectively, the top tray having
been flipped over and resting on the bottom tray, and here
including three vertically aligned sets of filled bottom and top
tray pairs;
[0049] FIG. 10 is a top plan view of an alternative embodiment of a
packing tray, having an angled floating pad disposed adjacent
opposite ends of the tray in each adjacent pocket of the tray.
DETAILED DESCRIPTION OF THE INVENTION
[0050] FIGS. 1-9 show a packing tray 10 according to one embodiment
of the invention. The packing tray 10 is formed from a single sheet
of plastic foam, here polystyrene foam, and is particularly
well-suited for packing stacks of nested conical ice cream cones or
stacks of other nested conical hollow objects. The present
embodiment is a non-limiting example of the invention.
[0051] FIGS. 1-4 show one tray 10 with empty pockets 20 in
perspective and various cross sectional views. FIGS. 5-9 show a
bottom tray 10B having pockets 20 each filled with a stack S of
nested cones C. FIGS. 8-9 show sets of stacked trays, each set
comprising a bottom tray 10B and a top tray 10T in vertically
stacked arrangement, collectively holding a stack S of cones C in
their combined pocket space 20S. The top and bottom trays are
identical in this embodiment, and are easily stacked as described
below for packing in an outer container 40 (FIG. 9).
[0052] The packing tray 10 has a plurality of recessed elongated
pockets 20 depending downwardly from a top wall 9, each pocket
formed to accommodate a stack S of nested ice cream cones C to be
packed therein (FIGS. 5-7). The tray top wall 9 is generally
rectangular shaped with a longitudinal (length) dimension X and a
lateral (width) dimension Y, and each pocket has an elongated axis
LA aligned parallel to the length direction X of the tray (FIG. 2).
The tray perimeter 6 is formed by two opposing longitudinal edges
5A and 5B, and two opposing lateral edges 5C and 5D, joined by four
rounded corners 41. The top wall 9 has a top peripheral surface 12
surrounding each of the four elongated pockets 20 and defining a
top reference plane TRP (FIGS. 2-7). Here the tray has four
elongated pockets, extending downwardly with respect to the TRP,
and the pockets are of the same configuration and dimensions.
[0053] The top peripheral surface 12 of the tray includes a flat
planar trim lip 11 separating the pockets from the perimeter 6 of
the top wall 9. The trim lip 11 extends around the entire perimeter
6 and completely circumscribes the array of elongated pockets 20
(FIGS. 1-9). When packed in a container 40 (e.g., for storage and
shipment) as shown in FIG. 9, the upper surface of the flat planar
trim lip 11B of a bottom tray 10B engages the upper surface of the
flat planar trim lip 11T of an adjacent top tray 10T, the top and
bottom trays being stacked vertically top to bottom (with the top
tray flipped 180 degrees with respect to the bottom tray) to form a
closed packing tray set enclosing a stack S of cones C disposed in
a combined pocket space 20S formed by the facing pockets 20T and
20B of the top and bottom trays respectively. The trim lip 11 rests
between the inner container wall 41 and the elongated pockets 20
(FIG. 9). This enables the trim lip to absorb a portion of any
impact on the container such as the normal jostling that occurs
during shipping. The trim lip 11 also provides a relatively easily
graspable point on the packing tray 10, whether of a single tray or
a tray set, by offering parallel grasping points at every point
along the perimeter 6 (FIGS. 1-8).
[0054] In accordance with the present invention, and as best shown
in FIGS. 5-6, a stack S of nested ice cream cones C (or other
hollow conical objects in a nested stack) can be fitted into each
recessed pocket 20 of the tray, wherein the stack of cones is
supported by both a bottom floating pad 14 and an angled floating
pad 15 in the pocket 20. The angled floating pad 15 supports an
outer cone OC of the stack of cones and the bottom floating pad 14
supports the remainder of the stack (FIG. 5-6). The angled floating
pad 15 is adjacent to a first end wall 31A of the pocket and the
bottom floating pad 14 is adjacent to an opposed second end wall
31B of the pocket. The pocket is generally rectilinear in shape,
wherein the two opposing end walls 31A and 31B are joined by two
opposing sidewalls 30A and 30B to form the generally rectilinear
shaped (in a plane parallel to the TRP) pocket.
[0055] The elongated pocket 20 is further defined as including an
elongated portion 27 and a conical portion 28, best shown in FIG.
5. The conical portion 27 is disposed adjacent the first end wall
31A and includes the angled floating pad 15 to support an outer
cone OC of the stack. The elongated portion 27 includes the bottom
floating pad 14 to support the remaining cones of the stack. A
bottom gap (first void space) 23G is defined by a downwardly
recessed wall portion 23 between the angled floating pad 15 and the
bottom floating pad 14, allowing the open top lip OCL of the outer
cone of the stack to hang freely between the two pads (FIG. 5). At
the other tip end of the outer cone, a first end wall gap 24G is
defined by a downwardly recessed wall portion 24 between the first
end wall 31A and the angled floating pad 15 to provide a second
void space for the outer cone tip OCT to hang in this second (first
end wall) gap 24G. These two gaps 23G and 24G, at either end of the
angled floating pad 15, provide protection for both ends of the
outermost cone, this being the cone generally subject to the
greatest applied forces.
[0056] Another feature of the tray is a foot support 45, best seen
in FIGS. 3-4 and 6-9. The foot support provides a flat planar
lowermost surface 46 for resting the tray on a flat surface (e.g.
in the bottom of a carton or on a tabletop), as well as providing a
flat planar mating surface for an adjacent stacked tray as shown in
FIGS. 8-9. In this embodiment, the foot support 45 is a lowermost
extending wall portion of the tray, including footer wall portions
25 forming sidewall gaps 25G adjacent each of the pocket sidewalls
30A and 30B (see FIGS. 1-2 and 8) that separate the sidewalls from
both the angled floating pad 15 and the bottom floating pad 14,
allowing the pads 14,15 to move transversely with respect to the
sidewalls 30. The foot support 45 (lowermost surface of the tray)
further includes wall portions 23 and 24 (previously described)
below the bottom gap 23G and first end wall gap 24G, as well as a
second end wall footer 26 (adjacent the second end wall 31B), to
form a perimeter footing 45 circumscribing the X-Y profile of each
pocket 20 (FIG. 8). The footing 45 provides a stable support
structure for the pockets 20 and a contact mating surface 46 for
adjacent trays of a stack 18 of trays (FIGS. 8-9). The footing 45
further enables movement between adjacent trays to dissipate
applied forces between the trays. For example, where the footing 45
of two trays are aligned between an upwardly facing tray 47 and a
downwardly facing tray 48 (FIGS. 8-9), forces are translated
between the trays through the footing 45 of each and then on into
the pocket sidewalls 30 rather than directly into the cones.
[0057] The pocket sidewalls 30A and 30B also have expandable
(accordion-like) flutes 13C aligned transversely to the TRP that
allow the sidewalls to expand and move in various directions in
response to applied forces, and to accommodate varying cone
diameters.
[0058] The bottom floating pad 14 comprises a bottom platform 21
connected by expandable (accordion-like) bottom flutes 13B to the
bottom wall 33. In a relaxed state, when the pocket is empty, the
bottom platform 21 is disposed above the bottom wall 33. When cones
are added to the pocket, the bottom flutes 13B allow the bottom
platform 21 to move downwardly toward the bottom wall 33, away from
the TRP. Bottom wall 33 has four sides, two opposing elongated
sides 33A and 33B running parallel to the elongated axis LA of the
pocket, and two opposing short sides 33C and 33D running parallel
to a transverse axis TA of the pocket (FIG. 2). The bottom flutes
13B are aligned parallel to the elongated axis LA and join the long
sides 33A and 33B of the bottom wall 33 to the bottom platform; the
short sides 33C and 33D of the bottom wall are joined to the bottom
platform by a non-fluted connecting member 52 (FIGS. 1-2). The long
sides 33A and 33B connect to the pocket sidewalls 30 and form the
sidewall gaps 25G along each sidewall 30A and 30B as previously
described (FIG. 2). This enables the bottom platform 21 to move
both along the transverse axis TA, as well as up and down
(transverse to TRP) as the bottom flutes 13B expand and contract
(FIG. 4, arrows A1 and A2).
[0059] The angled floating pad 15 comprises an angled platform 22
connected by expandable (accordion-like) flutes 13A to an angled
wall 34. The upwardly angled wall 34 is disposed at an acute angle
.alpha. to the TRP (see FIG. 3) and forms the generally conical
cross section (of the conical pocket portion 28) between the first
end wall 31A and the bottom wall 33 (FIG. 6). The bottom gap 23G
separates a lowermost end wall 34L of the angled wall 34 from the
bottom wall 33. The first end wall gap 24G separates an uppermost
end 34U of the angled wall form the first end wall 31A. The angled
platform 22 is circumscribed by the angled wall 34 and positioned
above the angled wall (in a relaxed state, pocket empty) by the
circumferential flutes 13A. The flutes join the angled platform 22
to the angled wall 34 and are aligned generally parallel to the TRP
(FIG. 3). The angled platform can move along all axes relative to
the angled wall (FIGS. 2-3 and/or 9--add arrows to show movement).
This complete range of movement allows the angled platform 22 to
shift to accommodate a multitude of cone lengths and widths. The
mobility of the angled platform 22 and the bottom platform 21
combined with the expanding sidewalls 30A and 30B allows the pocket
sidewalls 20 and platforms 22, 21 to move in response to applied
forces (e.g., jostling during transport), dissipating the forces
across the tray surfaces rather than transmitting the forces to the
cone stack.
[0060] A pair of bumpers 16A and 16B protrude inwardly from the
second end wall 31B and into the pocket recess (FIGS. 1-2 and 5).
Each bumper extends from the bottom wall 33 approximately halfway
up (moving toward the TRP) the end wall 31B. The bumpers are
aligned parallel to one another and disposed on either side of the
elongated center axis LA of the pocket 20. The end wall 31B is at
an acute angle .beta. to the TRP (FIG. 3). The innermost cone IC of
a stack of cones (disposed in the elongated pocket 20) rests with
its open top end lip ICL against (or in near proximity to) the
bumpers (FIG. 4). The bumpers 16A and 16B help absorb the impact of
any movement of the stack of cones along the elongated axis LA of
the pocket by compression of the foam tray material, or otherwise
deflecting such movement.
[0061] FIG. 8 illustrates a stack 18 comprising three sets 17A,
17B, 17C of packing trays, and FIG. 9 shows the stack of three sets
disposed in carton 40. A set 17 consists of two packing trays 20
stacked vertically one on top of the other, but with the top tray
flipped 180 degrees with respect to the bottom tray so that their
open pockets align and form a combined pocket space PS. More
specifically, the bottom tray 10B of the set is an upwardly facing
packing tray and the top tray 10T of the set is a downwardly facing
tray. The top tray is rotated 180 degrees about the TRP so that the
pockets 20B and 20T of the two trays combine to form a bounded
pocket space PS accommodating a nested stack S of cones C (FIG. 9).
Here the depth (transverse to TRP) of each pocket 20B and 20T is
one half of the open top end cone diameter, so that the innermost
cone IC is held snugly in the pocket about its widest
circumference. The packing sets 17 are placed in a vertical stack
18 (e.g., for shipping or storage) by placing one set on top of
another, with the tray footings 45 of adjacent sets in mating
planar engagement (FIGS. 8-9). This configuration allows a stack of
trays 18 to take advantage of the force dissipative construction of
the tray walls as described above. When shipped, a stack 18 of
trays are placed within a shipping container 40 such that the trim
lip 11 of each tray 10 will buffer the tray pockets 20 from the
container sidewalls 41S, absorbing any lateral jostling during
shipping. The footing 45 of the bottommost tray 10B then contacts
the container floor 41F, allowing any impacts through the floor of
the container to be translated up through the footing 45 and
dissipated into the tray walls as described earlier.
[0062] FIG. 10 is a top plan view of an alternative embodiment of a
packing tray 10', having four pockets 20' in a row and of the same
dimensions as FIG. 1, but with the angled floating pad 15' disposed
adjacent opposite ends 5C' and 5D' of the tray in each adjacent
pocket 20' of the tray.
[0063] Variations of the forgoing embodiments will be apparent to
the skilled person and are included in the disclosure and
claims.
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