Reusable envelope tray system

Abstract

A reusable envelope tray system includes a stacking tray with linear structural corrugations and a support unit. The tray bottom has parallel side fold lines extending along the corrugations and parallel end fold lines transverse to the corrugations. A sidewall extends upwardly from each bottom side fold line, and an end wall extends upwardly from each bottom end fold line. Each end wall has an outer portion connected to the bottom wall and an inner portion connected to the outer portion. Fold lines connect the inner and outer portions to provide a bearing surface during stacking. The outer portion includes a hand hole and the inner portion includes a return hinge extending transverse to the corrugations and reachable through the hand hole. The hinge allows bending of the inner portion under folding assembly/disassembly of the tray. The support unit has upstanding posts received in apertures on the tray bottom.

1 . A stacking tray formed from corrugated board or the like having linear structural corrugations between opposed faces:
 a) said tray having a bottom wall bounded by spaced apart, substantially parallel side fold lines extending along said corrugations, and spaced apart, substantially parallel end fold lines extending across and at substantially right angles to said corrugations;   b) a sidewall extending upwardly from each of said bottom wall side fold lines and an end wall extending upwardly from each of said bottom wall end fold lines; and   c) said end walls each being divided into an outer portion connected to said bottom wall and an inner portion connected to said outer portion.   
     
     
         2 . The stacking tray as set forth in  claim 1  wherein:
 a) said inner portion includes a return hinge extending transverse to said corrugations and allowing bending of said inner portion under folding assembly and/or disassembly of said tray. 
 
     
     
         3 . The stacking tray as set forth in  claim 2  wherein:
 a) said inner portion includes a tab extending from an end margin thereof; and 
 b) a slot positioned along each of said bottom wall end fold lines to receive said tab member and lock said inner portion in a position transverse to said bottom wall. 
 
     
     
         4 . The stacking tray as set forth in  claim 3  wherein said slot includes a space allowing said tab member to spring back against an inner margin of said slot after said tab member is received in said slot. 
     
     
         5 . The stacking tray as set forth in  claim 2  wherein:
 a) a pair of spaced apart fold lines form said inner and outer portion connection to provide a weight bearing surface during stacking. 
 
     
     
         6 . The stacking tray set forth in  claim 5  wherein:
 a) said spaced apart fold line connection includes a tab member; and 
 b) a slot positioned along each of said bottom end wall fold lines to receive the tab member of an underlying stacking tray. 
 
     
     
         7 . The stacking tray set forth in  claim 2  wherein a plurality of slits is disposed in spaced relation along each of said side fold lines to allow positioning of each said sidewall at a substantially right angle to said bottom wall. 
     
     
         8 . The stacking tray set forth in  claim 2  wherein:
 a) said outer portions each include an aperture to provide a handhold of said tray; and 
 b) said hinge is aligned with said aperture allowing bending of said inner portion by a user's hand. 
 
     
     
         9 . The stacking tray set forth in  claim 2  wherein:
 a) said sidewalls each include a pair of spaced apart, substantially parallel sidewall fold lines extending across and at substantially right angles to said corrugations; and 
 b) a pair of end flaps delineated by said fold lines, each of said end flaps forming a substantially right angled corner with one of said sidewalls and positioned between said outer and inner portions of said end wall of said tray. 
 
     
     
         10 . The stacking tray set forth in  claim 9  wherein:
 a) said outer portions each include a first aperture; 
 b) said end flaps each include an end cut-out; 
 c) said cut-outs cooperate to form a second aperture; 
 d) said first and second apertures are aligned to form a handhold; and 
 e) said inner portions each form a backstop for said apertures when said tray is assembled. 
 
     
     
         11 . The stacking tray as set forth in  claim 2  wherein:
 a) said bottom wall includes an aperture to receive a support member when said tray is in a flattened condition. 
 
     
     
         12 . A stacking tray formed from corrugated board or the like having linear structural corrugations between opposed faces:
 a) said tray having a bottom wall bounded by spaced apart, substantially parallel side fold lines extending along said corrugations, and spaced apart, substantially parallel end fold lines extending across and at substantially right angles to said corrugations;   b) a sidewall extending upwardly from each of said bottom wall side fold lines and an end wall extending upwardly from each of said bottom wall end fold lines;   c) said end walls each being divided into an outer portion connected to said bottom wall and an inner portion connected to said outer portion;   d) said sidewalls each include a pair of spaced apart, substantially parallel sidewall fold lines extending across and at substantially right angles to said corrugations;   e) a pair of end flaps delineated by said fold lines, each of said end flaps forming a substantially right angled corner with one of said sidewalls and positioned between said outer an inner portions of said end wall of said tray;   f) said inner portion includes a return hinge extending transverse to said corrugations and allowing bending of said inner portion under folding assembly and/or disassembly of said tray;   g) said inner portion includes a tab extending from an end margin thereof;   h) a slot positioned along each of said bottom wall end fold lines to receive said tab member and lock said inner portion in a position transverse to said bottom wall;   i) said spaced apart fold lines forming said connection include a tab member; and   j) a slot positioned along each of said bottom end wall fold lines to receive the tab member of an underlying stacking tray.   
     
     
         13 . The stacking tray as set forth in  claim 12  wherein:
 a) a pair of spaced apart fold lines form said inner and outer portion connection to provide a weight bearing surface during stacking. 
 
     
     
         14 . The stacking tray as set forth in  claim 12  wherein:
 a) said outer portions each include an aperture to provide a handhold; and 
 b) said hinge is aligned with said aperture allowing bending of said inner portion by a user's hand. 
 
     
     
         15 . The stacking tray as set forth in  claim 12  wherein a plurality of slits is disposed in spaced relation along each of said side fold lines to allow positioning of each said sidewall at a substantially right angle to said bottom wall. 
     
     
         16 . The stacking tray as set forth in  claim 12  wherein:
 a) said bottom wall includes an aperture to receive a support member when said tray is in a flattened condition. 
 
     
     
         17 . The stacking tray as set forth in  claim 12  wherein:
 a) said outer portions each include a first aperture: 
 b) said end flaps each include an end cut-out; 
 c) said end cut-outs cooperate to form a second aperture; 
 d) said first and second apertures are aligned to form a handhold; and 
 e) said inner portions each form a backstop for said apertures when said tray is assembled. 
 
     
     
         18 . A stacking tray system comprising:
 a) a stacking tray formed from corrugated board or the like having linear structural corrugations between opposed faces:   b) said tray having a bottom wall bounded by spaced apart, substantially parallel side fold lines extending along said corrugations, and spaced apart, substantially parallel end fold lines extending across and at substantially right angles to said corrugations;   c) a sidewall extending upwardly from each of said bottom wall side fold lines and an end wall extending upwardly from each of said bottom wall end fold lines;   d) said end walls each being divided into an outer portion connected to said bottom wall and an inner portion connected to said outer portion;   e) said inner portion includes a return hinge extending transverse to said corrugations and allowing bending of said inner portion under folding assembly and/; or disassembly of said tray;   f) a tray support structure having a post connected to a base; and   g) said bottom wall including an aperture for receiving said post to support said tray in a flattened condition.   
     
     
         19 . The stacking tray system as set forth in  claim 18  wherein:
 a) said support structure includes a plurality of wheels. 
 
     
     
         20 . The stacking tray system as set forth in  claim 19  wherein:
 a) said support structure includes a handle.