GB2327941A

GB2327941A - Article-retaining trays

Info

Publication number: GB2327941A
Application number: GB9816679A
Authority: GB
Inventors: Michael Christopher Embleton; Jeffrey Graham Pitt
Original assignee: FORMOLD Ltd
Current assignee: FORMOLD Ltd
Priority date: 1997-08-02
Filing date: 1998-07-30
Publication date: 1999-02-10
Also published as: GB9816679D0

Abstract

Article retaining trays 3 of a stack (Figure 1) are each formed by two thermoplastics sheets 20 and 21 bonded together back to back, sheet 20 providing thermoformed socket recesses 7 for the bottoms of articles 1 standing on the tray, and sheet 21 providing thermoformed socket recesses 11 for the tops of articles 1 beneath in the stack. The bond between the sheets 20 and 21 extends throughout their flat, peripheral margin and throughout areas between the recesses 7. In an alternative construction of tray (Figures 5 and 6), twin sheets 33 and 34, which are bonded together back to back peripherally and along a lattice of pinch lines 39, are flat inside thermoformed peripheral rims 35 and 37 for article-constraint. The articles 1 may be bottles, cans or cartons.

Description

Article-Retaining Trays This invention relates to article-retaining trays.

The invention is especially concerned with trays of the kind for use in retaining bottles or other articles in array side by side with one another as one of a plurality of such arrays stacked one upon the other for storage and/or transit. Trays of this kind are used, for example, for the safe and stacked transport of bottles from the bottle manufacturer to drinks or other manufacturers where they are to be filled and closed.

They may also be used for transporting the filled and closed bottles from the manufacturers to retailers and for storage and display-for-sale of the bottles there.

It is an object of the present invention to provide an improved construction of tray of the general kind specified above.

According to one aspect of the present invention there is provided a tray for use in retaining bottles or other articles in array side by side with one another as one of a plurality of such arrays stacked one upon the other for storage and/or transit of the articles, wherein the tray comprises two sheets of plastics material bonded together back to back to define, respectively, upper and under surfaces of the tray, the sheet defining the upper surface being configured to receive bottom portions of the articles in restraining them in said array on the tray, and the sheet defining the under surface being configured to engage the tops of articles of a corresponding array beneath the tray in restraining lateral movement between them and the tray.

The sheet defining the upper surface may be configured to present recesses, channels or troughs for receiving and locating the bottom portions of the bottles or other articles, and the sheet defining the under surface may be configured to present recesses or channels for nesting the tray on the tops of the bottles or other articles beneath. However, the upper and/or under surfaces may be substantially flat within a full or partial peripheral rim. In the latter circumstances, the sheet defining the upper surface may be configured with an upstanding peripheral rim for constraining the bottom portions of the bottles or other articles on the tray, and the sheet defining the under surface may be configured to have a downwardly depending peripheral rim for correspondingly constraining the tops of the articles beneath, to the tray.

The use of two sheets of plastics material welded or otherwise bonded back to back has the advantage that the upper and under surfaces of the tray can be thermoformed or otherwise moulded to have configurations that are independent of one another. In particular, recesses, channels, troughs or rims for receiving and constraining the bottoms and tops of the bottles or other articles, and ridges or other features for strengthening, may be configured into one surface of the tray without affecting the configuration of the other surface. Moreover, the use of two sheets bonded together enables stronger trays of thermoformed plastics sheet to be produced more economically that by use of thicker sheet material.

The invention is especially applicable to the storage and/or transit of bottles whether empty or filled. In this respect, and according to a feature of the present invention there is provided a tray for use in retaining bottles in array side by side with one another as one of a plurality of such arrays stacked one upon the other for storage and/or transit of the bottles, wherein the tray comprises two sheets of plastics material bonded together back to back to define, respectively, upper and under surfaces of the tray, the sheet defining the upper surface being configured to receive bottom portions of the bottles for locating and restraining them in said array on the tray, and the sheet defining the under surface being configured to present recesses or channels for nesting the tray on the tops of a corresponding array of bottles beneath.

Furthermore, and in accordance with another aspect of the present invention there is provided a stack of bottles or other articles wherein a plurality of arrays of rows of the articles are stacked one upon the other with each array above the lowermost standing on an upper surface of an individual tray that itself stands on the tops of the articles of an array immediately beneath it in the stack, wherein each tray comprises two sheets of plastics material bonded together back to back to define, respectively, upper and under surfaces of the tray, the sheet defining the upper surface being configured to receive bottom portions of the articles on the tray in restraining them in their array, and the sheet defining the under surface being configured to engage the tops of the articles of the array beneath for restraining lateral movement between them and the tray.

A bottle-stack and two forms of bottle-retaining tray for use therein, all in accordance with the present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 shows part of the bottle-stack as loaded on a pallet and including five identical bottle-retaining trays of a first of the two forms according to the present invention; Figures 2 and 3 are plan views from above and below respectively of part of one of the trays used in the stack of Figure 1; Figure 4 is a longitudinal sectional view of part of the tray of Figures 2 and 3 when in use within the stack of Figure 1; Figure 5 is a perspective view from above of the second form of tray according to the invention; and Figure 6 is a sectional view of part of a bottle-stack corresponding to Figure 1, incorporating the form of tray of Figure 5.

The two forms of tray to be described are shown in use for stacked storage and/or transit of bottles that are empty and without closure caps, however the principles embodied in these forms of tray and the methods of their construction are equally applicable to the provision of trays adapted for the stacked storage and/or transit of filled and capped bottles.

Referring to Figure 1, three hundred identical bottles 1 are loaded together on a wooden pallet 2 to stand upright side by side with one another in five 5 x 12 rectangular arrays that are stacked one upon the other. Five identical trays 3 are included in the stack to locate and retain the bottles 1 together in the five arrays.

A tray 3 of the first, bottom array of the stack stands directly on the pallet 2 with the bottles 1 of that array standing upright side by side in the tray 3, and with a tray 3 of the second array standing on the tops of those bottles 1. The bottles 1 of the second array similarly stand upright in their tray 3, and a third tray 3 of the next, third array stands on them. This stacking arrangement in which each successive array of bottles 1 stands in its individual tray 3 on the array beneath, is repeated for the third to fifth arrays. Five trays 3 are used for the five arrays, and a sixth tray (not shown) stands on the tops of the bottles 1 in the fifth, uppermost array, to top off the stack; this tray may be of the same form as the trays 3, but as an alternative may have the special form described in GB-A-2291408 for topping-off the stack.

Referring now also to Figures 2 to 4, each tray 3 has an upper surface 4 that is recessed to receive the bases of the bottles 1 of its array, and an under surface 5 that is recessed to nest on the tops of the bottles 1 below.

The tray 3 has a flat peripheral margin or rim and its upper surface 4 as shown in Figures 2 and 4, is configured with annular shoulders 6 to define a 5 x 12 rectangular array of regularly-spaced sockets or recesses 7 that are generally circular in form. Each socket recess 7 is shaped to conform closely to the shaping around the bottle-base so that the individual bottle 1 received by that recess 7 is supported firmly to stand upright and side by side with, but spaced slightly from, the bottles 1 received by the adjacent recesses 7 of the tray 3.

The configuration of the tray 3 in its under surface 5 defines as shown in Figures 3 and 4, annular shoulders 10 which are located in register with the recesses 7 and which each circumscribe a central, socket recess 11.

Each recess 11 is generally cylindrical to conform closely to the shaping of the bottle-top, and from within the shoulder 10 may have a surrounding flank that flares down in diameter into the recess 11. Flaring down of the flanks to the recesses 11 may be adopted to assist with the nesting of the tray 3 on the tops of the bottles 1 of the array below.

The bottles 1 of each array, as they stand separated from one another in the upper-surface socket recesses 7 of their respective tray 3, are afforded positive location and individual support by that tray. This, coupled with the constraint on those same bottles 1 provided through their individual engagement in the under-surface socket recesses 11 of the tray 3 nesting on top, ensures that the array as a whole is firmly held. The interlocking of the bottles 1 provided by the trays 3 from array to array throughout the whole stack, endows the stack with a significant measure of rigidity and stability.

The tray is thermoformed from two sheets 20 and 21 of thermoplastics material (for example, high-impact polystyrene, polypropylene, high-density polyethylene, acrilonitrile-butadiene-styrene or polycarbonate). Each sheet 20 and 21, which for example, may have a thickness of 2 mm, is thermoformed over a respective mould, the mould in the case of the sheet 20 conforming positively (with allowance for sheet thickness) to the configuration of the upper surface 4 required, and the mould for the sheet 21 conforming correspondingly to the configuration of the under surface 5 required. The two sheets 20 and 21 are thermoformed from two plain sheets that are loaded together, one upon the other, into the thermoforming machine to be heated. The mould tools for the upper and under surfaces 4 and 5 are brought together onto the two heated sheets. Air is then injected between the two sheets as they are formed in the moulds, the air being exhausted through small holes in the sheets. While they are still hot the sheets are firmly pressed together to weld them to one another throughout the peripheral margin and within the lattice of areas where they abut between the socket recesses 7. Once the sheets 20 and 21 welded together have been trimmed, the tray can be put into service.

The strength and durability of the tray constructed as described above, enables it to be re-used repeatedly for the secure storage and transport of bottles. Although with the form of tray described above, the bottles are held in arrays of regimented rows and columns, they may be nested with one another more closely using channels or troughs as described in GB-A-2257121 or GB-A-2274833.

Alternatively, the bottles may be packed tightly against one another on the tray within a rim upstanding from the upper surface and a rim depending from the under surface.

The second tray, to be described with reference to Figures 5 and 6, is of this form.

Referring to Figures 5 and 6, the upper and under surfaces 30 and 31 of the tray 32 in this case are defined by thermoformed sheets 33 and 34 respectively.

The sheet 33 is substantially flat apart from at its periphery where it is configured to define an upstanding rim 35; the rim 35 acts to constrain the bottoms of bottles 36 standing on the surface 30 from sliding from the tray 32. Similarly, the sheet 34 is substantially flat apart from at its periphery where it is configured to define a downwardly depending rim 37 which acts to retain the tray 32 securely located on the tops of the bottles 36 below. The rim 37 is set inwardly slightly from the edge of the sheet 34 leaving a small, flat peripheral margin 38 to the sheet 34; this inward location of the rim 37 ensures that the tops of the bottles 36 are more tightly constrained than otherwise would be the case and that lateral movement between them and the tray 32 is effectively restrained. Either or both of the rims 35 and 37 may be scalloped along its length, conforming in part to the bottle-bottoms and tops respectively so that the outer bottles 36 of each array nest against the rim.

The bonding of the two thermoformed sheets 33 and 34 together is effected in this case with distinct welds between them along a grid or lattice of pinch-bond lines 39. Moreover, the edge of sheet 33 at the rim 35 is welded to the margin 38 of the sheet 34 so as to ensure that the sheets 33 and 34 and their rims 35 and 37 are firmly as one with one another. Instead of welding, adhesive may be used to bond the sheets 33 and 34 together.

The use of twin sheets 20 and 21, and 30 and 31, bonded together gives the respective trays 3 and 32 significant strength. The configuration of the sheets 20 and 21 with the shoulders 6 and 10 and their firm bonding together back to back around the peripheral margin and throughout the lattice between the recesses 7, ensures substantial rigidity for the tray 3. Also, the rims 35 and 37 and the lattice of pinch-bonds 39 contribute good rigidity to the tray 32. The trays 3 and 32 are in this respect well able to support and retain filled bottles during transportation and storage in the stack, and also when the stack is opened up for display and sale of the bottles from the stack within a retail establishment.

Although the trays 3 and 32 described above are for use with bottles, the invention, and in particular the tray 32, can be readily applied to retention in side-by-side array of other articles such as cartons, cans and other packs of liquid and other foodstuffs.

Claims

Claims:

1. A tray for use in retaining bottles or other articles in array side by side with one another as one of a plurality of such arrays stacked one upon the other for storage and/or transit of the articles, wherein the tray comprises two sheets of plastics material bonded together back to back to define, respectively, upper and under surfaces of the tray, the sheet defining the upper surface being configured to receive bottom portions of the articles in restraining them in said array on the tray, and the sheet defining the under surface being configured to engage the tops of articles of a corresponding array beneath the tray in restraining lateral movement between them and the tray.

2. A tray according to Claim 1 wherein the sheet defining the upper surface is configured to present recesses, channels or troughs for receiving and locating the bottom portions of the articles on the tray.

3. A tray according to Claim 2 wherein the sheet defining the upper surface is configured with socket recesses for receiving the bottom portions of respective ones of the articles on the tray.

4. A tray according to any one of Claims 1 to 3 wherein the sheet defining the under surface is configured to present recesses or channels for nesting the tray on the tops of the articles beneath.

5. A tray according to Claim 4 wherein the sheet defining the under surface is configured with socket recesses for receiving respective ones of said tops.

6. A tray according to Claim 1 wherein the upper and/or under surface is substantially flat within a full or partial peripheral rim.

7. A tray according to Claim 1 or Claim 6 wherein the sheet defining the upper surface is configured with an upstanding peripheral rim for constraining the bottom portions of the articles on the tray in said array.

8. A tray according to any one of Claims 1 to 3, 6 and 7 wherein the sheet defining the under surface is configured to have a downwardly depending peripheral rim for constraining the tops of the articles beneath, to the tray.

9. A tray for use in retaining bottles in array side by side with one another as one of a plurality of such arrays stacked one upon the other for storage and/or transit of the bottles, wherein the tray comprises two sheets of plastics material bonded together back to back to define, respectively, upper and under surfaces of the tray, the sheet defining the upper surface being configured to receive bottom portions of the bottles for locating and restraining them in said array on the tray, and the sheet defining the under surface being configured to present recesses or channels for nesting the tray on the tops of a corresponding array of bottles beneath.

10. A tray according to Claim 9 having a flat peripheral margin.

11. A tray according to any one of Claims 1 to 10 wherein the bond between the two sheets extends throughout the peripheral margin of the tray and throughout a lattice of areas inwardly of the margin.

12. A stack of bottles or other articles wherein a plurality of arrays of rows of the articles are stacked one upon the other with each array above the lowermost standing on an upper surface of an individual tray that itself stands on the tops of the articles of an array immediately beneath it in the stack, wherein each tray comprises two sheets of plastics material bonded together back to back to define, respectively, upper and under surfaces of the tray, the sheet defining the upper surface being configured to receive bottom portions of the articles on the tray in restraining them in their array, and the sheet defining the under surface being configured to engage the tops of the articles of the array beneath for restraining lateral movement between them and the tray.

13. A stack according to Claim 12 wherein the sheet defining the upper surface of the tray is configured to present recesses, channels or troughs for receiving and locating the bottom portions of the articles on the tray.

14. A stack according to Claim 13 wherein the sheet defining the upper surface of the tray is configured with socket recesses for receiving the bottom portions of respective ones of the articles on the tray.

15. A stack according to any one of Claims 12 to 14 wherein the sheet defining the under surface of the tray is configured to present recesses or channels for nesting the tray on the tops of the articles beneath.

16. A stack according to Claim 15 wherein the sheet defining the under surface of the tray is configured with socket recesses for receiving respective ones of said tops.

17. A stack according to Claim 12 wherein the upper and/or the under surface of the tray is substantially flat within a full or partial peripheral rim.

18. A stack according to Claim 12 or Claim 17 wherein the sheet defining the upper surface of the tray is configured with an upstanding peripheral rim for constraining the bottom portions of the articles on the tray in said array.

19. A stack according to any one of Claims 12 to 14, 17 and 18 wherein the sheet defining the under surface of the tray is configured to have a downwardly depending peripheral rim for constraining the tops of the articles beneath, to the tray.

20. A tray for use in retaining bottles in array side by side with one another as one of a plurality of such arrays stacked one upon the other for storage and/or transit of the bottles, substantially as hereinbefore described with reference to Figures 2 to 4, or Figures 5 and 6, of the accompanying drawings.

21. A stack of bottles wherein a plurality of arrays of rows of the bottles are stacked one upon the other on individual trays, substantially as hereinbefore described with reference to Figures 1 to 4, or Figures 1, 5 and 6, of the accompanying drawings.