WO2018226697A1

WO2018226697A1 - Stackable caseless tray system for retaining vertical layers of packaged material

Info

Publication number: WO2018226697A1
Application number: PCT/US2018/036062
Authority: WO
Inventors: Kendal MALSTROM
Original assignee: Integrated Packaging Machinery, LLC
Priority date: 2017-06-06
Filing date: 2018-06-05
Publication date: 2018-12-13

Abstract

A stackable caseless tray system includes a plurality of stacking trays that are operable between stacked and nested positions. Each stacking tray includes a base member that supports a layer of product from below. First and second sets of vertical supports extend downward from respective first and second edges of the base member. First and second pluralities of nesting apertures defined within the first and second edges, respectively. The stacked position is defined by vertical supports of the first and second sets of vertical supports being vertically and axially aligned with the vertical supports of a vertically adjacent tray. The nested position is defined by the vertical supports of the first and second vertical supports being vertically and axially aligned with corresponding nesting apertures of the vertically adjacent tray.

Description

STACKABLE CASELESS TRAY SYSTEM FOR RETAINING VERTICAL

LAYERS OF PACKAGED MATERIAL

FI ELD OF THE I NVENTION

[0001] The present invention generally relates to package handling trays, and more

specifically, stackable package handling trays for storing multiple layers of packaged products.

BACKGROUND OF THE I NVENTION

[0002] Within warehouse settings, products to be sold or transported need to be stacked to save space and also for transporting various products from one location to another. One type of packaging tray is a product tray having a caseless design. Typically, conventional forms of these trays rest on top of a single layer of product and then support a vertically adjacent layer of product from below. The various conventional trays reside between vertically adjacent layers of product and do not touch one another. The conventional trays serve to vertically align layers of product and the vertical loads exerted by the layers of product are carried by and through the layers of product positioned below. The lowest layer of product, in turn, carries the vertical load of all of the layers of product positioned above.

SUMMARY OF THE I NVENTION

[0003] According to one aspect of the present invention, a stackable caseless tray system includes a plurality of stacking trays that are operable between stacked and nested positions. Each stacking tray includes a base member that supports a layer of product from below. First and second sets of vertical supports extend downward from respective first and second edges of the base member. First and second pluralities of nesting apertures are defined within the first and second edges, respectively. The stacked position is defined by vertical supports of the first and second sets of vertical supports being vertically and axially aligned with the vertical supports of a vertically adjacent tray. The nested position is defined by the vertical supports of the first and second vertical supports being vertically and axially aligned with corresponding nesting apertures of the vertically adjacent tray. [0004] According to another aspect of the present invention, a stackable caseless tray includes a base member having first and second edges and that selectively supports a layer of product from below. A first set of vertical supports extends downward from the first edge. A second set of vertical supports extending downward from the second edge. A first plurality of nesting apertures is defined within the base member proximate the first edge. A second plurality of nesting apertures is defined within the base member proximate the second edge. The base member at the first and second sets of vertical supports is configured to receive and support vertical supports of a vertically adjacent tray to define a stacked position. The vertical supports of the vertically adjacent tray are configured to pass through the first and second pluralities of nesting apertures to define a nesting position. The nesting position is further defined by the vertically adjacent tray being rotated 180 degrees from the stacked position.

[0005] According to another aspect of the present invention, a stackable caseless tray includes first and second sets of vertical supports having a base extending therebetween. A first plurality of nesting apertures is defined within the base and in an alternating pattern with the first set of vertical supports. A second plurality of nesting apertures is defined within the base and in an alternating pattern with the second set of vertical supports. The base is configured to receive a vertically adjacent tray in alternative stacked and nesting positions. The vertical supports of the vertically adjacent tray align with the first and second sets of vertical supports in the stacked position. The vertical supports of the vertically adjacent tray align with the first and second pluralities of nesting apertures in the nesting position.

[0006] These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In the drawings:

[0008] FIG. 1 is a front perspective view of an aspect of the stackable caseless tray

system shown in a stacked position and holding the plurality of layers of product;

[0009] FIG. 2 is a front perspective view of the stackable caseless tray system shown in the nested position; [0010] FIG. 3 is a front perspective view of one of the stackable caseless trays of the stackable caseless tray system;

[0011] FIG. 4 is a top perspective view of an aspect of the stackable caseless tray for the stackable caseless tray system;

[0012] FIG. 5 is a side elevational view of the stackable caseless tray of FIG. 4;

[0013] FIG. 6 is a bottom plan view of the stackable caseless tray of FIG. 4;

[0014] FIG. 7 is an elevational view of the stackable caseless tray system shown in the nested position;

[0015] FIG. 8 is an enlarged elevational view of the stackable caseless tray system of FIG.

7, taken at area VII I;

[0016] FIG. 9 is a top perspective view of the stackable caseless tray system of FIG. 7 shown in the stacked position and holding various layers of product therein;

[0017] FIG. 10 is a top plan view of the stackable caseless tray system of FIG. 9;

[0018] FIG. 11 is a first elevational view of the stackable caseless tray system of FIG. 9;

[0019] FIG. 12 is a second elevational view of the stackable caseless tray system of FIG. 9;

[0020] FIG. 13 is a third elevational view of the stackable caseless tray system of FIG. 9;

[0021] FIG. 14 is a top perspective view of an alternative aspect of the stackable caseless tray for the stackable caseless tray system;

[0022] FIG. 15 is a front elevational view of the stackable caseless tray of FIG. 14;

[0023] FIG. 16 is a bottom plan view of the stackable caseless tray of FIG. 14;

[0024] FIG. 17 is a side elevational view of the stackable caseless tray system of FIG. 14 shown in the nested position;

[0025] FIG. 18 is an enlarged elevational view of the stackable caseless tray system of

FIG. 17, taken at area XVI II;

[0026] FIG. 19 is a top perspective view of the stackable caseless tray system of FIG. 14 shown in the stacked position and holding various layers of product therein;

[0027] FIG. 20 is a top plan view of the stackable caseless tray system of FIG. 19;

[0028] FIG. 21 is a first elevational view of the stackable caseless tray system of FIG. 19;

[0029] FIG. 22 is a second elevational view of the stackable caseless tray system of FIG.

19;

[0030] FIG. 23 is a third elevational view of the stackable caseless tray system of FIG. 19; [0031] FIG. 24 is a side perspective view of the stackable caseless tray system of FIG. 7 shown in a compact nested configuration;

[0032] FIG. 25 is a perspective exploded view of the stackable caseless tray system of

FIG. 24;

[0033] FIG. 26 is an elevational view of the system of FIG. 24;

[0034] FIG. 27 is a side elevational view of an aspect of the stackable caseless tray system shown in a stacked position and containing various products stored therein;

[0035] FIG. 28 is a side perspective view of the stackable caseless trays of FIG. 27;

[0036] FIG. 29 is a side elevational view of an aspect of the stackable caseless trays shown in the stacked position and containing product therein;

[0037] FIG. 30 is a side perspective view of the stackable caseless trays of FIG. 29;

[0038] FIG. 31 is a top perspective view of an aspect of a stackable caseless tray for the stackable caseless tray system;

[0039] FIG. 32 is a side elevational view of the stackable caseless tray of FIG. 31;

[0040] FIG. 33 is a bottom plan view of the stackable caseless tray of FIG. 31;

[0041] FIG. 34 is an enlarged elevational view of a vertical support for the stackable caseless tray of FIG. 32;

[0042] FIG. 35 is an elevational view of stackable caseless trays similar to those shown in

FIG. 31 and shown in a nested position;

[0043] FIG. 36 is an enlarged elevational view of the stackable caseless trays of FIG. 35, taken at area XXVI;

[0044] FIG. 37 is a top perspective view of an aspect of a stackable caseless tray for the stackable caseless tray system;

[0045] FIG. 38 is a side elevational view of the stackable caseless tray of FIG. 37;

[0046] FIG. 39 is a bottom plan view of the stackable caseless tray of FIG. 38;

[0047] FIG. 40 is an enlarged elevational view of a vertical support for the stackable caseless tray of FIG. 38 taken at area XL;

[0048] FIG. 41 is a side elevational view of a set of stackable caseless trays similar to the stackable caseless tray of FIG. 37 and shown in a nested position;

[0049] FIG. 42 is an enlarged elevational view of the stackable caseless trays of FIG. 41 taken at area XLII; [0050] FIG. 43 is a side perspective view of an aspect of the stackable caseless trays shown in the nested position and shown positioned on a rolling pallet;

[0051] FIG. 44 is a first side elevational view of the stackable caseless trays of FIG. 43; and

[0052] FIG. 45 is a second side elevational view of the stackable caseless trays of FIG. 43.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0053] For purposes of description herein, the terms "upper," "lower," "right," "left,"

"rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the invention as oriented in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0054] As shown in FIGS. 1-26, reference numeral 10 generally refers to a stackable

caseless tray system that incorporates a plurality of stackable caseless trays 12 for holding various pre-packaged products 14 for storage and movement within a warehouse setting, within vehicles, and within various transportation devices within warehouse and retail settings. According to the various aspects of the device, the stackable caseless tray system 10 includes a plurality of stacking caseless trays 12 that are stackable in a plurality of configurations. The plurality of configurations can include, at least, a stacked position 16 and a nested position 18. As will be described more fully below, various

configurations of the stackable caseless tray system 10 can also include a compact nested position 20.

[0055] Referring again to FIGS. 1-26, each stackable caseless tray 12 can include a base member 30 for supporting a single layer 32 of product 14 from below. The base member

30 can include first and second pluralities 34, 36 of nesting apertures 38 that are positioned at least at opposing first and second edges 40, 42 of the base member 30, respectively. According to various aspects of the device, nesting apertures 38 can also be disposed at opposing third and fourth edges 44, 46 of the base member 30. A first set 48 of vertical supports 50 are included within each stackable caseless tray 12. The first set 48 of vertical supports 50 extend downward from the base member 30. The first plurality 34 of nesting apertures 38 and the first set 48 of vertical supports 50 are positioned along the first edge 40 of the base member 30. The first set 48 of vertical supports 50 are adapted to rest on top of a corresponding first set 52 of vertical supports 50 of a vertically adjacent tray 54 when in the stacked position 16. A second set 56 of vertical supports 50 extends downward from the base member 30. The second plurality 36 of nesting apertures 38 and the second set 56 of vertical supports 50 are positioned along the second edge 42 of the base member 30. The second set 56 of vertical supports 50 are adapted to rest on top of a corresponding second set 58 of vertical supports 50 of the vertically adjacent tray 54 in the stacked position 16, similar to the first set 48 of vertical supports 50.

[0056] The vertical supports 50 of the first set 48 of vertical supports 50 correspond to the nesting apertures 38 of the second plurality 36 of nesting apertures 38. Stated another way, there are an equal number of vertical supports 50 and nesting apertures 38 within the first set 48 of vertical supports 50 and the second plurality 36 of nesting apertures 38. In this manner, when the various stackable caseless trays 12 are in the nested position 18, the first set 48 of vertical supports 50 extends through the second plurality 36 of nesting apertures 38 to define the nested position 18. Similarly, the vertical supports 50 of the second set 56 of vertical supports 50 correspond to the nesting apertures 38 of the first plurality 34 of nesting apertures 38. Accordingly, the second set 56 of vertical supports 50 and the first plurality 34 of nesting apertures 38 include equal numbers of vertical supports 50 and nesting apertures 38. Again, in the nested position 18, the second set 56 of vertical supports 50 extends through the first plurality 34 of nesting apertures 38 to define the nested position 18.

[0057] Referring again to FIGS. 1-26, the first and second sets 48, 56 of vertical supports

50 may include different numbers of vertical supports 50. As exemplified in the figures, the first set 48 of vertical supports 50 can include three vertical supports 50, with two nesting apertures 38 positioned in an alternating pattern therebetween. Similarly, the second set 56 of vertical supports 50 can include two vertical supports 50 that are spaced in an alternating pattern between three nesting apertures 38. In this manner, the first set 48 of vertical supports 50 and the first plurality 34 of nesting apertures 38 are positioned along the first edge 40 of the base member 30 in an alternating configuration. Similarly, the second set 56 of vertical supports 50 and the second plurality 36 of nesting apertures 38 are positioned in an alternating configuration along the second edge 42 of the base member 30.

[0058] Referring now to FIGS. 1, 9 and 19, in the stacked position 16, the various

stackable caseless trays 12 are positioned such that each of the first and second sets 48, 56 of vertical supports 50 are vertically aligned with one another. In this manner, each vertical support 50 of the first set 48 of vertical supports 50 among the stackable caseless trays 12 define segmented columns 70 that extend along and through each of the first edges 40 of the stackable caseless trays 12. Similarly, the second set 56 of vertical supports 50 in the stacked position 16 are in vertical alignment. Accordingly, each of the vertical supports 50 of the various second sets 56 of vertical supports 50 among the stackable caseless trays 12 define a plurality of segmented columns 70 that extend along and through each of the second edges 42 of the stackable caseless trays 12. The segmented columns 70 are vertically continuous and serve to transfer vertical loads 76 from each of the stackable caseless trays 12 through the first and second edges 40, 42 of each tray, through the segmented columns 70 and into the ground or into a rolling pallet 78 positioned below the plurality of stackable caseless trays 12 in the stacked position 16. Stated another way, in the stacked position 16, the first edge 40 of the stacking caseless tray 12 is positioned in vertical alignment with the various first edges 40 of the vertically adjacent trays 54. Similarly, the second edge 42 of the stackable caseless tray 12 is in vertical alignment with the various second edges 42 of all of the vertically adjacent trays 54 to form the segmented columns 70 that carry the vertical loads 76 of the stackable caseless trays 12 and also of the products 14 contained within the stackable caseless trays 12.

[0059] Referring again to FIGS. 1-26, each of the vertical supports 50 of the first and second sets 48, 56 include an enlarged top surface 64 that tapers to a foot portion 62 at the bottom of each vertical support 50. In the stacked position 16, each of the stackable caseless trays 12, with the exception of the uppermost stackable caseless tray 12, includes vertical supports 50 having a foot portion 62 of a vertically adjacent tray 54 that is seated on top of the enlarged top surface 64 of each vertical support 50 of a vertically adjacent tray 54. In this stacked position 16, where product 14 is disposed within the base member 30 of the various stackable caseless trays 12, the vertical load 76 of a single layer 32 of the product 14 is carried by the base member 30 and then is transferred outward to each of the vertical supports 50. These vertical loads 76 are then transferred down each of the vertical supports 50 and through the engagement between the foot portion 62 of one vertical support 50 and through the enlarged top surface 64 of a vertically adjacent vertical support 50. These vertical loads 76 are continually transferred by the segmented columns 70 until they are transferred into the ground or into a rolling pallet 78 or other similar pallet member disposed beneath the vertical stacked unit 80 of stackable caseless trays 12.

[0060] According to various aspects of the device, by having the vertical loads 76

transferred through the segmented columns 70, the vertical loads 76 are kept away, or are substantially kept away, from the product 14 stored or contained within the stackable caseless trays 12. In this manner, vertical loads 76 are not directed through, or are not substantially directed through, the various products 14 contained therein. By allowing the vertical loads 76 to be transferred through the segmented columns 70 of the stackable caseless trays 12, the product packaging that can be stored and transported within the stackable caseless trays 12 does not need to be as robust, or as thick, to account for the transfer of vertical loads 76 that is typically experienced in use of conventional trays. By allowing the product packaging to be less structurally robust, money and resources can be saved in producing product packaging for various products 14. Through the use of the stackable caseless tray system 10, money and resources can be saved in the manufacture and use of product packaging where the product packaging is not required to carry vertical loads 76 of multiple layers 32 of additional product 14 that may rest on top of a particular product 14 when being stored and/or transported.

[0061] Additionally, the stackable caseless trays 12 can be continually reused and

recycled. The stackable caseless trays 12 are typically made of a plastic or other similar polymer material that can be easily washed, cleaned, sanitized and generally maintained. The plastic nature of the stackable caseless trays 12 also allows for the possibility of recycling material in the event of damage, breakage or excessive wear.

[0062] According to various aspects of the device, a wide range of products 14 can be stored and/or transported within the stackable caseless tray system 10, a typical limitation being the height of the product 14. Typically, the height of the product should be less than the height between base members 30 of vertically adjacent stackable caseless trays 12 when in the stacked position 16.

[0063] As exemplified in the figures, the product 14 contained therein is a beverage container, and typically a milk carton that is stored in a compact rectangular array within each of the base members 30 of each of the stackable caseless trays 12. In this exemplary instance, each layer 32 of product 14 can include a substantial amount of weight. In the stackable caseless tray system 10, the weight of each layer 32 of product 14 is received by the base member 30. This weight of each layer 32 of product 14 is then transferred through the plurality of stackable caseless trays 12 in the stacked position 16 by transferring the vertical load 76 through each of the vertical supports 50. As discussed above, the vertical supports 50 are configured to define segmented columns 70 of the stacked unit 80 of the stackable caseless tray system 10. It is contemplated that wide varieties of products 14 can be contained within the stackable caseless tray system 10. Such products 14 can include, but are not limited to, beverage containers, frozen foods, dry goods, merchandise, most any type of food packaging, combinations thereof, and other similar items stored and transported within and between warehouse areas, retail areas and commercial areas.

[0064] According to various aspects of the device, the caseless tray 12 may have vertical supports 50 that can be removed, replaced or modified to accommodate varying types, shapes and heights of product 14. The vertical supports 50 can be permanent and fixed, or can be removable, selectively removable, extendable and otherwise adaptable relative to the base member 30 to conform to the products 14 and various needs of the user.

[0065] Referring again to FIGS. 1-26, the stackable caseless tray system 10, when not in use, can be manipulated to define the nested position 18. In the nested position 18, one of the stackable caseless trays 12 can be rotated with respect to vertically adjacent trays 54 within the stacked unit 80 of caseless trays 12. In this manner, the vertical supports 50 of the first set 48 that are aligned along the first edge 40 of a stackable caseless tray 12 are vertically aligned with a second edge 42 of a vertically adjacent tray 54. In turn, the vertical supports 50 of the first set 48 are aligned with the second plurality 36 of nesting apertures 38 that are disposed along the second edge 42 of a vertically adjacent tray 54. In the nested position 18, the vertical supports 50 of the first set 48 extend through the second plurality 36 of nesting apertures 38 of the vertically adjacent tray 54.

[0066] In various embodiments, as exemplified in FIGS. 2, 7, 8, 17, 18 and 25, the foot portions 62 of the vertical supports 50 of the first set 48 engage the enlarged top surfaces 64 of a corresponding first set 52 of vertical supports 50 of a distally adjacent tray 90. The distally adjacent tray 90 is defined by a stackable caseless tray 12 that is above or below a vertically adjacent stackable caseless tray 12. In this manner, in the nested position 18, the vertical loads 76 of the stackable caseless trays 12 are still transferred through the vertical supports 50 of the stackable caseless trays 12 to the floor or to a base pallet or rolling pallet 78. However, the segmented columns 70 in the nested position 18 are defined by vertically alternating sets 92 of stackable caseless trays 12. These vertically alternating sets 92 are generated because the nested position 18 is formed by rotating every alternating stackable caseless tray 12 a certain rotation. In this manner, the vertical supports 50 of vertically adjacent trays 54 are no longer in alignment. Rather, with respect to vertically adjacent trays 54 of the stacked unit 80, each of the vertical supports 50 aligns with a corresponding nesting aperture 38 so that each of the vertical supports 50 extend through the corresponding nesting apertures 38 to engage vertical supports 50 of a distally adjacent tray 90 that are in alignment with the vertical supports 50 of the corresponding stackable caseless tray 12.

[0067] Referring now to FIGS. 2-13, one aspect of the stackable caseless trays 12 includes a rectangular configuration where the opposing first and second edges 40, 42 of the stackable caseless tray 12 are longer than the opposing third and fourth edges 44, 46 of the stackable caseless tray 12. In this embodiment, the nested position 18 is defined by 180 degrees rotation of each vertically alternating stackable caseless tray 12.

Accordingly, as exemplified in FIG. 2, the nested position 18 of the stackable caseless trays 12 defines multiple segmented columns 70 of vertical supports 50. Only half of these vertical supports 50 form load columns 100 that engage the ground and transfer vertical loads 76 of the stackable caseless trays 12 into a supporting substrate. The remaining segmented columns 70 are idle columns 102 that are typically elevated above the supporting substrate.

[0068] Referring now to FIGS. 14-26, various configurations of the stackable caseless trays 12 can be square such that the opposing first and second edges 40, 42 of the stackable caseless tray 12 are the same length as the opposing third and fourth edges 44, 46 of the stackable caseless tray 12. In such an embodiment, nesting apertures 38 can also be included within the third and fourth edges 44, 46. Typically, the nesting apertures 38 within the third and fourth edges 44, 46 correspond to the total number of vertical supports 50 contained within the first and second edges 40, 42. This

configuration allows the nested configuration to be achieved by rotating each vertically adjacent stackable caseless tray 12 only 90 degrees. By rotating each stackable caseless tray 12 only 90 degrees, a compact nested position 20 can be achieved as exemplified in FIGS. 24 and 26. In this compact nested position 20, each vertical support 50 is adapted to extend through nesting apertures 38 of up to three sequentially and vertically adjacent trays 54 and come to rest on an enlarged top surface 64 of a vertical support 50 that is in the same alignment as the stackable caseless tray 12. The compact nested position 20 can result in one set of load columns 100 that engage a supporting substrate and up to three sets of idle columns 102 that are elevated at various heights above the supporting substrate. The stackable caseless trays 12 are typically made of light materials having little mass so that the load of a stacked unit 80 of caseless trays 12 in the nested position 18 and the compact nested position 20 can be supported by only a portion of the caseless trays 12 that represent the load columns 100.

[0069] According to various aspects of the device as exemplified in FIGS. 1-25, the

number of vertical supports 50 in the first and second sets 48, 56 of vertical supports 50 are typically alternating in configuration. By way of example, and not limitation, a first set 48 of vertical supports 50 can include two vertical supports 50 and the second set 56 of the vertical supports 50 can include three vertical supports 50. Accordingly, when the stackable caseless trays 12 are rotated 180 degrees, the first set 48 of vertical supports 50 can fit between the second set 56 of vertical supports 50 to engage nesting apertures 38 defined in alternating configuration between the various vertical supports 50 along the first and second edges 40, 42 of the stackable caseless tray 12.

[0070] It should be understood that the first and second sets 48, 56 of vertical supports

50 can include other configurations of vertical supports 50. As exemplified in the figures, the alternating configurations are shown where the second set 56 of vertical supports 50 has one more vertical support 50 than the first set 48 of vertical supports 50. It should be understood that other configurations of vertical supports 50 are contemplated. In each configuration, rotation of the stackable caseless trays 12 of a certain rotational distance results in the nested position 18. This nested position 18 is defined when the vertical supports 50 are out of alignment with vertically adjacent vertical supports 50 but are in alignment with the vertically adjacent nesting apertures 38 of the vertically adjacent trays 54 in the stacked unit 80 of caseless trays 12. Additionally, the caseless trays 12 can be formed as any one of various shapes such that the base member 30 can be any one of various shapes. Such shapes can include, but are not limited by, triangular, rectilinear, hexagonal, circular, polygons that can be arranged in a tessellated pattern, irregular shapes, combinations thereof, and other similar shapes.

[0071] Referring again to FIGS. 1-25, each of the stackable caseless trays 12 can include at least one lateral reinforcement, typically in the form of first and second lateral reinforcements 110, 112 that extend below the first and second edges 40, 42, respectively. In such an embodiment, the first lateral reinforcement 110 can extend along the first edge 40 and between, as well as beyond, the vertical supports 50 of the first set 48 of vertical supports 50. Similarly, the second lateral reinforcement 112 can extend along the second edge 42 and extend between, as well as beyond, the vertical supports 50 of the second set 56 of vertical supports 50. The first and second lateral reinforcements 110, 112 serve to resist deflection of the base member 30 in at least one direction. Additionally, in various embodiments, where the compact nested position 20 is achievable, the first and second lateral reinforcements 110, 112 can be adapted to rest upon the base member 30 of a vertically adjacent tray 54 within the stacked unit 80. It is also contemplated that engagement between the first and second lateral reinforcements 110, 112 and the base member 30 of a vertically adjacent tray 54 can be achieved in the nested position 18 where the compact nested position 20 may not be achievable.

[0072] To further assist the stackable caseless tray system 10 in resisting deflection

within each of the base members 30 of the various stackable caseless trays 12, each stackable caseless tray 12 can include a plurality of elongated ribs 120 positioned at an underside of the base member 30 and that extend between the first and second edges

40, 42 of each stackable caseless tray 12. The elongated ribs 120 may also extend between the third and fourth edges 44, 46 instead of, or in addition to, extending between the first and second edges 40, 42 of each stackable caseless tray 12.

Additionally, the elongated ribs 120 are typically positioned perpendicular to the first and second lateral reinforcements 110, 112, such that each base member 30 can be reinforced to resist deflection in multiple directions.

[0073] As exemplified in FIGS. 1-25, each of the stackable caseless trays 12 can include a perimetrical lip 130 that extends upward from the base member 30. The perimetrical lip 130 can define a boundary 132 that extends around the first and second sets 48, 56 of vertical supports 50 and also around the first and second pluralities 34, 36 of nesting apertures 38. In this manner, in each of the nested and stacked positions 18, 16, the vertical supports 50 can be located within the boundary 132 that is defined within the perimetrical lip 130. According to various aspects of the device, the first and second sets 48, 56 of vertical supports 50 and the first and second pluralities 34, 36 of nesting apertures 38 may also define at least a portion of the perimetrical lip 130.

[0074] According to various aspects of the device, the tapered configuration of the

vertical supports 50 can be tapered in multiple directions such that the foot portions 62 of each of the vertical supports 50 are thinner and/or narrower than the enlarged top surface 64 of the vertical support 50. This tapered configuration of each vertical support 50 can assist in guiding each of the vertical supports 50 through the corresponding nesting apertures 38 to define the nested position 18 of the stackable caseless tray system 10. The enlarged top surface 64 may define a detent or concave formation that assists in locating a corresponding foot portion 62 into engagement to define the stacked, nested and compact nested positions 16, 18, 20.

[0075] Referring again to FIGS. 1-26, along the first and second edges 40, 42 of each stackable caseless tray 12, the foot portions 62 of each vertical support 50 and the adjacent nesting apertures 38 are positioned to be aligned along the first and second edges 40, 42, respectively. In this manner, when the stackable caseless trays 12 are rotated to define the nested position 18, the foot portions 62 of the vertical supports 50 can conveniently slide within the nesting apertures 38 to define the nested position 18. This configuration also maintains alignment of the vertical supports 50 in both the nested and stacked positions 18, 16. Accordingly, in each of the nested and stacked positions 18, 16, a foot portion 62 of each vertical support 50 rests upon a corresponding enlarged top surface 64 of another vertical support 50, with the exception of the lowermost stackable caseless tray 12, which typically rests on a supporting substrate. [0076] Referring again to FIGS. 2, 7 and 17, the nested position 18 of the stackable caseless tray system 10 can be defined by vertically alternating sets 92 of the stackable caseless trays 12 that are vertically and rotationally aligned with one another. In the compact nested position 20, it is contemplated that up to four sets of stackable caseless trays 12 can be defined, where each of up to four sets of stackable caseless trays 12 are in vertical and rotational alignment with one another.

[0077] According to various aspects of the device, the stackable caseless trays 12 can be made of plastic and can be molded via various molding procedures that can include, but are not limited to, injection molding, compression molding, blow molding, combinations thereof and other similar molding procedures. It is also contemplated that the stackable caseless trays 12 can be made of composite materials that include both metal and plastic.

[0078] According to various aspects of the device, the stackable caseless trays 12 can include a plurality of product aligning apertures 140 that are included within each of the base members 30. The product aligning apertures 140 are positioned to allow a top section of the products 14 in a particular layer 32 to extend into or through the base member 30 placed above the layer 32 of products 14. In this manner, the product aligning apertures 140 laterally secure the product 14 in the layer 32 by laterally retaining the top section of the product 14 therein. The product aligning aperture 140 also allows the top portion of the product 14 to at least partially pass or extend into and potentially through the base member 30 so that little if any portion of a bottom surface of the base member 30 rests upon a top portion or top surface of the layer 32 of product 14 below. Accordingly, the product aligning apertures 140 assist in directing the vertical forces 76 from the vertically adjacent layer 32 of product 14 through the base member 30 and outward to the vertical supports 50. This serves to minimize the amount of the vertical load 76 that is directed through the product 14 itself. Stated another way, each base member 30 supports a layer 32 of product 14 from below. This support may result in a certain downward deflection of the base member 30. The product aligning apertures 140 defined within the base member 30 allow the base member 30 to flex downward without resting upon the top section or top surface of product 14 below the base member 30. During the deflection of the base member 30, the product aligning apertures 140 may vertically slide around the top section of the product 14 below. [0079] In various aspects of the device, the top section of the product 14 may be a cap of the product as in a beverage bottle or a top edge of the product 14 as in a beverage carton. The product aligning apertures 140 may be sized to be slightly larger and have a similar shape to laterally retain the layer 32 of products 14 in a particular array. By laterally retaining the products 14 in this manner, the product 14 may be difficult to remove from a layer 32 of product 14 that is not at the top of the stacked unit 80 of caseless trays 12. In this manner, a user is encouraged to completely remove an entire layer 32 of product 14 from the top of the stacked unit 80 of caseless trays 12 before removing an empty caseless tray 12 at the top of the stacked unit 80 and then entirely removing the next layer 32 of product 14. This configuration can help to ensure a preferred sequence of storage and stacking operations that can cooperate or coincide with expiration dates of products 14. The product aligning apertures 140 can be sized and located to carry a particular product 14. It is also contemplated that the product aligning apertures 140 can be configured as a grid of lateral supports that may support a wide variety of products 14 within a single type of caseless tray 12.

[0080] It is also contemplated that the product aligning apertures 140 can be used to drain fluid through a single caseless tray 12 or through a stacked unit 80 of caseless trays 12 in the stacked, nested or compact nested positions 16, 18, 20. Accordingly, any leakage within any one or more of the product packages stored therein can drain through the stackable caseless trays 12. Additionally, the product aligning apertures 140 allow for easy cleaning and/or sanitizing of the stackable caseless trays 12, when necessary. The product aligning apertures 140 also allow for cleaning of the stackable caseless trays 12 in either the stacked position 16, the nested position 18, the compact nested position 20, or individually. Accordingly, when cleaned, the stackable caseless trays 12 can be wheeled into a cleaning and/or sanitizing area on a single pallet, or as the single stacked unit 80. The stacked unit 80 of stackable caseless trays 12 can be cleaned and/or sanitized, without disassembling the stacked unit 80 and then reassembling afterwards. Accordingly, the stacked unit 80 of stackable caseless trays 12 can be maintained in this configuration until such time as the stackable caseless trays 12 are needed for storing and/or transporting various products 14. [0081] In conventional trays, because the trays are positioned between layers 32 of the products 14, and no vertical engagement exists, these conventional trays can result in swaying and/or lateral displacement of stacks of product 14.

[0082] As exemplified in FIGS. 1-26, because the stackable caseless tray system 10

includes a vertical engagement of the various vertical supports 50 of each of the vertical caseless trays 12, this swaying and lateral deflection of the stacked unit 80 is substantially minimized. Accordingly, vertical forces 76 can be transferred through the various vertical supports 50. Additionally, the lateral forces can also be received and counteracted through the vertical engagement of each of the stackable caseless trays 12. The positioning of the segmented columns 70, defined by the stacked unit 80 of stackable caseless trays 12, positions the segmented columns 70 outside and generally surrounding the layers 32 of the product 14 such that lateral reinforcement of the layers 32 of product 14 is achieved through the configuration of the stackable caseless trays 12 in the stacked position 16. In this manner, the stackable caseless trays 12 form a frame 160 between and around the layers 32 of product 14 to individually support each layer 32 of product 14 and also laterally support the various layers 32 of product 14 through the engagement of each of the stackable caseless trays 12 within the stacked unit 80 via the vertical supports 50.

[0083] Referring now to FIGS. 27-45, various aspects of the stackable caseless trays 12 can include vertical supports 50 having a stepped configuration 170. This stepped configuration 170 can include a locking tooth 172 that is defined within the foot portion 62 of each vertical support 50. This locking tooth 172 is adapted to be secured within a corresponding tooth recess 174 defined within the enlarged top surface 64 of a corresponding vertical support 50 of a lower vertically adjacent tray 54. As exemplified in FIG. 27, the locking tooth 172 may extend through the tooth recess 174 defined within the enlarged top surface 64 of the vertical support 50 of the vertically adjacent tray 54. In this manner, the engagement of the locking tooth 172 and the tooth recess 174 can substantially fix the relative positions of the vertically adjacent trays 54. This

configuration also limits sliding and twisting that might occur when product 14 is loaded onto the stackable caseless trays 12 in the stacked position 16.

[0084] Referring again to FIGS. 27-45, the vertical supports 50 having the stepped

configuration 170 can include a plurality of shoulders 180 that engage a vertically adjacent tray 54 in the stacked position 16 or the nested position 18 or can be adapted to engage a rolling pallet 78 in the nested position 18. The various shoulders 180 of the vertical support 50 having the stepped configuration 170 can include an upper shoulder

180 in the form of a positive stop 182 that is adapted to engage a vertically adjacent tray

54 in the nested position 18. Accordingly, various vertical loads 76 can be transferred through vertically adjacent trays 54 where the positive stop 182 of a vertical support 50 of a caseless tray 12 rests upon an outer edge 184 of a nesting aperture 38 of a vertically adjacent tray 54. In this configuration, the positive stop 182 is larger than the nesting aperture 38, such that the positive stop 182 engages the outer edge 184 of the nesting aperture 38 and rests thereon. This configuration allows for the transmission of the vertical loads 76 in the nested position 18 to be moved through the various load columns

100. Additionally, a lower shoulder 186 can be adapted to engage a nesting aperture 38 defined within a rolling pallet 78 to define secondary load columns 188 that can be used to transfer vertical loads 76 into the rolling pallet 78. In this configuration, the lower shoulder 186 is adapted to be wider than a nesting aperture 38 defined within the rolling pallet 78. The nesting aperture 38 in the rolling pallet 78 receives the lower shoulder 186 such that a distally adjacent tray 90 can have a vertical support 50 that extends through a vertically adjacent tray 54 so that the lower shoulder 186 can engage an outer edge 184 of the nesting aperture 38 defined within the rolling pallet 78. Accordingly, in the nested position 18, substantially all of the vertical supports 50 can define a load column 100 for transferring various vertical loads 76 through the stacked unit 80 of caseless trays 12 disposed within the nested position 18. Additionally, this configuration minimizes the number of idle columns 102 in the nested position 18 so that the vertical loads 76 can be delivered more evenly throughout the stacked unit 80 of caseless trays 12 and into the rolling pallet 78. Additionally, while the nested position 18 is typically for storage of the stackable caseless trays 12, product 14 having a lower profile can be stored between the caseless trays 12 in the nested position 18.

As exemplified in FIGS. 36 and 42, the locking tooth 172 of the foot portion 62 of each vertical support 50, when the stackable caseless trays 12 are in the stacked position

16, can engage a tooth recess 174 defined within a corresponding enlarged top surface

64 of a vertical support 50 for one of the vertically adjacent trays 54 and, where applicable, the rolling pallet 78 on which the lowest caseless tray 12 rests. As discussed previously, the engagement of the locking tooth 172 and the tooth recess 174 substantially locks in the lateral position of each vertical support 50 of each caseless tray 12 in the stacked position 16.

[0086] Referring again to FIGS. 27-45, each vertical support 50 can include a tapered reinforcement 210 that extends along a face member 222 of each vertical support 50. These tapered reinforcements 210 are defined within a surface 212 of each vertical support 50 and adds structural rigidity to each vertical support 50 for transferring vertical loads 76 within the stacked unit 80 of caseless trays 12. The tapered reinforcement 210 also provides rigidity to each vertical support 50 for resisting bending, torsion, and other non-vertical forces that might be exerted upon the stacked unit 80 of caseless trays 12. Accordingly, where an individual pushes a stacked unit 80 of stackable caseless trays 12 set within a rolling pallet 78, the user may push the stack of caseless trays 12 in the stacked position 16 at a side of the stackable caseless trays 12. Using this pushing force, various lateral forces, twisting forces, moments, and other non-vertical forces might be applied on the stackable caseless trays 12. The various tapered reinforcements 210 as well as the stepped configuration 170 of the vertical supports 50, allows the vertical supports 50 to resist these vertical and non-vertical forces that might be experienced by the stackable caseless trays 12. Accordingly, the stepped configuration 170 of the vertical supports 50 and the tapered reinforcement 210 within the vertical supports 50 adds structural rigidity and strength to each of the vertical supports 50 to increase the robustness of the stackable caseless tray system 10.

[0087] Referring now to FIGS. 29-42, the elongated ribs 120, the vertical supports 50 and the first and second lateral reinforcements 110, 112 can cooperate to define a unitary structural formation 220 that extends throughout each caseless tray 12. As exemplified in FIGS. 33 and 39, each vertical support 50 includes a face member 222 that defines the tapered reinforcement 210 and at least one angled flange 224 or multiple angled flanges

224 that extend outward from the face member 222. The elongated ribs 120 extend between the angled flanges 224 so that an angled flange 224 at one side of the caseless tray 12 extends to an angled flange 224 on the opposing side of the caseless tray 12. In this manner, the unitary structural formation 220 extends from an underside of the base member 30 and defines an undulating formation that extends in a generally serpentine and continuous formation throughout the base member 30 of the caseless tray 12. This unitary structural formation 220 can also define the first and second lateral

reinforcements 110, 112 of a stackable caseless tray 12. This unitary structural formation 220 defines a substantially continuous structure that can be used to absorb various forces exerted by product 14 or users, or outside conditions, upon the caseless tray system 10 in the stacked or nested positions 16, 18. Additionally, because the elongated ribs 120 are connected between the vertical supports 50, each vertical support 50 is tied together through the elongated ribs 120 of the unitary structural formation 220.

Accordingly, vertical and non-vertical forces experienced by one vertical support 50 of a caseless tray 12 may be transferred via the elongated ribs 120 as well as the first and second lateral reinforcements 110, 112 to the other vertical supports 50 in the caseless tray 12. In this manner, the unitary structural formation 220 is configured to resist forces along multiple axes and about multiple points of rotational torque.

[0088] Referring again to FIGS. 27-45, the tapered reinforcement 210 of each vertical support 50 can further define the nested position 18 of the stackable caseless trays 12. When the caseless trays 12 are positioned in the nested position 18, the tapered reinforcements 210 of the vertical supports 50 of the load columns 100 and the idle columns 102 are aligned and the tapered configuration of the tapered reinforcements 210 can nest within one another to further secure the caseless trays 12 in the nested position 18. Accordingly, the nested position 18 is defined by the vertical supports 50 extending through a nesting aperture 38 of a vertically adjacent tray 54 and also having the tapered reinforcements 210 seat within one another to define a nesting

configuration in multiple directions. These structural reinforcements defined within the vertical supports 50 in the form of the stepped configuration 170, the locking tooth 172, the angled flanges 224 and the tapered reinforcement 210 can allow the material of the vertical supports 50 to be made thinner than where the vertical supports 50 are substantially planar in shape.

[0089] According to various aspects of the device, the vertical supports 50 can also be shaped in an arcuate manner to provide additional support and rigidity to the vertical supports 50. It should be understood that additional configurations of the vertical supports 50 can be utilized to add strength and rigidity to the vertical support 50 in transferring vertical loads 76 and non-vertical loads 76 among the various vertical supports 50 of the caseless tray system 10. [0090] Additionally, the vertical supports 50 may be tapered in cross section, such that an enlarged top surface 64 of each vertical support 50 at the tapered reinforcement 210 has a greater material thickness than the foot portion 62 of the corresponding vertical support 50. Alternatively, the material thickness of the vertical support 50 can remain consistent throughout the entire height of the vertical support 50. In such a

configuration, the enlarged top surface 64 has a greater cross-sectional area, but not necessarily a greater cross-sectional thickness of material. The shape of a vertical support 50 in the form of the angled flanges 224, the stepped configuration 170 and the tapered reinforcement 210 may define a substantially consistent material thickness throughout the vertical support 50.

[0091] Referring now to FIGS. 33 and 39, the tooth recesses 174 and the nesting

apertures 38 defined within the base member 30 of each caseless tray 12 may be a single elongated opening. Alternatively, in the case of the nesting apertures 38, the nesting apertures 38 will typically be shaped in the same configuration as the cross section of the vertical support 50. In this manner, the nesting aperture 38 will include angled sections 230 that are adapted to receive the angled flanges 224 of the vertically adjacent vertical support 50 from a vertically adjacent tray 54. By utilizing these angled sections 230 of the nesting aperture 38, the openings will be less likely to fold along the non-linear configuration of the nesting aperture 38. Accordingly, additional rigidity can be maintained while allowing apertures through the base member 30 for receiving the vertical supports 50 of vertically adjacent trays 54 in the nested position 18 and also for receiving the locking tooth 172 in a stacked position 16.

[0092] It is to be understood that variations and modifications can be made on the

aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

Claims

What is claimed is:

1. A stackable caseless tray system comprising:

a plurality of stacking trays that are operable between stacked and nested positions, each stacking tray comprising:

a base member that supports a layer of product from below; first and second sets of vertical supports extending downward from respective first and second edges of the base member; and

first and second pluralities of nesting apertures defined within the first and second edges, respectively; wherein

the stacked position is defined by vertical supports of the first and second sets of vertical supports being vertically and axially aligned with the vertical supports of a vertically adjacent tray; and

the nested position is defined by the vertical supports of the first and second vertical supports being vertically and axially aligned with corresponding nesting apertures of the vertically adjacent tray.

2. The stackable caseless tray system of claim 1, wherein the first and second pluralities of nesting apertures are positioned in an alternating pattern with the respective first and second sets of vertical supports.

3. The stackable caseless tray system of any one or more of claims 1-2, wherein the first edge includes three vertical supports and two nesting apertures, and wherein the second edge includes two vertical supports and three nesting apertures.

4. The stackable caseless tray system of any one or more of claims 1-3, wherein third and fourth edges of the base member include respective pluralities of nesting apertures.

5. The stackable caseless tray system of any one or more of claims 1-4, wherein a compact nested position is defined by the first and second sets of vertical supports being vertically and axially aligned with the third and fourth pluralities of nesting apertures of the vertically adjacent tray.

6. The stackable caseless tray system of any one or more of claims 1-5, wherein the vertical supports are integrally formed as part of the base member.

7. The stackable caseless tray system of any one or more of claims 1-6, wherein the vertical supports of the plurality of stacking trays in the stacked position define a plurality of segmented columns.

8. The stackable caseless tray system of any one or more of claims 1-7, wherein the base member includes at least one lateral reinforcement that extends at least between the first set of vertical supports and between the second set of vertical supports.

9. The stackable caseless tray system of any one or more of claims 1-8, wherein the base member includes a plurality of product aligning apertures that are configured to laterally align product within the vertically adjacent tray.

10. The stackable caseless tray system of claim 9, wherein the product aligning apertures are further configured to allow product to at least partially pass into the product aligning aperture and substantially prevent engagement between a bottom surface of the base member and a top surface of the product in the vertically adjacent tray.

11. A stackable caseless tray comprising:

a base member having first and second edges and that selectively supports a layer of product from below;

a first set of vertical supports extending downward from the first edge;

a second set of vertical supports extending downward from the second edge; a first plurality of nesting apertures defined within the base member proximate the first edge;

a second plurality of nesting apertures defined within the base member proximate the second edge; wherein the base member at the first and second sets of vertical supports is configured to receive and support vertical supports of a vertically adjacent tray to define a stacked position;

the vertical supports of the vertically adjacent tray are configured to pass through the first and second pluralities of nesting apertures to define a nesting position; and

the nesting position is further defined by the vertically adjacent tray being rotated 180 degrees from the stacked position.

12. The stackable caseless tray of claim 11, wherein each vertical support of the first and second sets of vertical supports includes a face member having at least one angled flange.

13. The stackable caseless tray of any one or more of claims 11-12, wherein each vertical support includes a tapered reinforcement, the tapered reinforcement extending from the base member to a foot of a respective vertical support.

14. The stackable caseless tray of claim 12, wherein each nesting aperture of the first and second pluralities of nesting apertures includes an angled section that is adapted to receive the angled flange of a respective vertical support of the vertically adjacent tray.

15. The stackable caseless tray of any one or more of claims 11-14, wherein the first and second pluralities of nesting apertures are positioned in an alternating relationship with the respective first and second sets of vertical supports.

16. The stackable caseless tray of any one or more of claims 11-15, wherein the first edge includes three vertical supports and two nesting apertures, and wherein the second edge includes two vertical supports and three nesting apertures.

17. The stackable caseless tray of any one or more of claims 11-16, wherein third and fourth edges of the base member include third and fourth pluralities of nesting apertures.

18. The stackable caseless tray of any one or more of claims 11-17, wherein a compact nesting position is defined by the first and second sets of vertical supports being vertically and axially aligned with the third and fourth pluralities of nesting apertures of the vertically adjacent tray.

19. The stackable caseless tray of any one or more of claims 11-18, wherein the first and second sets of vertical supports are integrally formed as part of the base member.

20. The stackable caseless tray of any one or more of claims 11-19, wherein the vertical supports of a plurality of stacking trays in the stacked position defines a plurality of segmented columns.

21. The stackable caseless tray of any one or more of claims 11-20, wherein the base member includes at least one lateral reinforcement that extends at least between the first set of vertical supports and between the second set of vertical supports.

22. The stackable caseless tray of any one or more of claims 11-21, wherein the base member includes a plurality of product aligning apertures that are configured to laterally align product within the vertically adjacent tray.

23. The stackable caseless tray of claim 22, wherein the product aligning apertures are further configured to allow product to at least partially pass into the product aligning aperture and substantially prevent engagement between a bottom surface of the base member and a top surface of the product in the vertically adjacent tray.

24. The stackable caseless tray of any one or more of claims 11-23, wherein the base member includes a plurality of ribs that are defined within an underside of the base member.

25. The stackable caseless tray of claim 24, wherein the plurality of ribs are positioned substantially perpendicular to the at least one lateral reinforcement.

26. The stackable caseless tray of any one or more of claims 24-25, wherein the plurality of ribs and the at least one lateral reinforcement are a substantially continuous structure that extends from the underside of the base member.

27. The stackable caseless tray of any one or more of claims 11-26, wherein the base member includes a recess that is configured to receive a foot of a respective vertical support of the vertically adjacent tray.

28. The stackable caseless tray of claim 27, wherein each vertical support of the first and second sets of vertical supports includes a locking tooth that is configured to be received within a corresponding recess of a lower vertically adjacent tray.

29. A stackable caseless tray comprising:

first and second sets of vertical supports having a base extending therebetween; a first plurality of nesting apertures defined within the base and in an alternating pattern with the first set of vertical supports;

a second plurality of nesting apertures defined within the base and in an alternating pattern with the second set of vertical supports; wherein

the base is configured to receive a vertically adjacent tray in alternative stacked and nesting positions;

the vertical supports of the vertically adjacent tray align with the first and second sets of vertical supports in the stacked position; and

the vertical supports of the vertically adjacent tray align with the first and second pluralities of nesting apertures in the nesting position.

30. The stackable caseless tray of claim 29, wherein each vertical support of the first and second sets of vertical supports includes a face member having at least one angled flange.

31. The stackable caseless tray of any one or more of claims 29-30, wherein each vertical support includes a tapered reinforcement, the tapered reinforcement extending from the base to a foot of a respective vertical support.

32. The stackable caseless tray of claim 30, wherein each nesting aperture of the first and second pluralities of nesting apertures includes an angled section that is adapted to receive the angled flange of a respective vertical support of the vertically adjacent tray.

33. The stackable caseless tray of any one or more of claims 29-32, wherein the first and second pluralities of nesting apertures are positioned in an alternating relationship with the respective first and second sets of vertical supports.

34. The stackable caseless tray of any one or more of claims 29-33, wherein a first edge of the base includes three vertical supports and two nesting apertures, and wherein a second edge of the base includes two vertical supports and three nesting apertures.

35. The stackable caseless tray of any one or more of claims 29-34, wherein third and fourth edges of the base include third and fourth pluralities of nesting apertures.

36. The stackable caseless tray of any one or more of claims 29-35, wherein a compact nesting position is defined by the first and second sets of vertical supports being vertically and axially aligned with the third and fourth pluralities of nesting apertures of the vertically adjacent tray.

37. The stackable caseless tray of any one or more of claims 29-36, wherein the vertical supports of the first and second sets are integrally formed as part of the base member.

38. The stackable caseless tray of any one or more of claims 29-37, wherein the vertical supports of the plurality of stacking trays in the stacked position defines a plurality of segmented columns.

39. The stackable caseless tray of any one or more of claims 29-38, wherein the base includes at least one lateral reinforcement that extends at least between the first set of vertical supports and between the second set of vertical supports.

40. The stackable caseless tray of any one or more of claims 29-39, wherein the base includes a plurality of product aligning apertures that are configured to laterally align product within the vertically adjacent tray.

41. The stackable caseless tray of claim 40, wherein the product aligning apertures are further configured to allow product to at least partially pass into the product aligning aperture and substantially prevent engagement between a bottom surface of the base member and a top surface of the product in the vertically adjacent tray.

42. The stackable caseless tray of any one or more of claims 29-41, wherein the base includes a plurality of ribs that are defined within an underside of the base.

43. The stackable caseless tray of claim 42, wherein the plurality of ribs are positioned substantially perpendicular to the at least one lateral reinforcement.

44. The stackable caseless tray of any one or more of claims 42-43, wherein the plurality of ribs and the at least one lateral reinforcement are a substantially continuous structure that extends from an underside of the base member.

45. The stackable caseless tray of any one or more of claims 29-44, wherein the base member includes a recess that is configured to receive a foot of a respective vertical support of a vertically adjacent tray.

46. The stackable caseless tray of claim 45, wherein the each vertical support of the first and second sets of vertical supports includes a locking tooth that is configured to be received within a corresponding recess of a lower vertically adjacent tray.