Nestable trays with minimum axial spacing

Abstract

A molded container of solid continuous construction having a floor and contiguous upstanding sidewalls angling outward and upward to a surrounding upper lip. Below the upper lip the floor and sidewalls surround an inner cavity adapted to receive food. The sidewalls include at least three outwardly-directed lugs that are thicker from an inner surface to an outer surface thereof than a nominal wall thickness of the remainder of the sidewalls. The sidewall at the location of each lug having an inner surface which is contiguous and uninterrupted relative to the inner surface of adjacent portions of the sidewall. Consequently, a first container may be stacked and nested within a second container such that the lugs on the first container contact the inner surface of the second container at the location of the lugs on the second container and maintain a predetermined axial spacing between the first and second containers.

1 . A food container system, including:
 a wet press molded container of solid continuous construction of fibrous material, the container having a floor and contiguous upstanding sidewalls angling outward at draft angles and upward to an upper lip, wherein the container is rectangular and has four sidewalls each having at least one lug that projects in or out from an adjacent portion of the respective sidewall and has a lug thickness greater from a projecting surface to a base surface on an opposite face of the sidewall than a nominal wall thickness of the adjacent portion of the respective sidewall, the floor and sidewalls surrounding an inner cavity below the upper lip adapted to receive food, wherein each lug has a lateral width of at least 0.2 inches and no more than 1 inch and each lug is teardrop shaped with a mass weighted toward a lower end, wherein a first molded container may be stacked within a second molded container such that the lugs on the first container contact the inner surface of the second container at the location of the lugs on the second container and maintain a predetermined axial spacing between the first and second containers.   
     
     
         2 . The food container system of  claim 1 , wherein each of the sidewalls has two of the lugs spaced apart closer to adjacent corners than to each other. 
     
     
         3 . The food container system of  claim 1 , wherein each of the sidewalls has two of the lugs spaced apart from adjacent corners no less than ⅕ and no greater than ⅓ of the total dimension of the respective sidewall from the corner. 
     
     
         4 . The food container system of  claim 1 , wherein each of the sidewalls has two of the lugs, and wherein a first pair of identical sidewalls opposite one another has lugs with base surfaces which are contiguous and uninterrupted relative to the surface of adjacent portions of the sidewall. 
     
     
         5 . The food container system of  claim 4 , wherein all of the lugs project outward, and all have inner base surfaces which are contiguous and uninterrupted relative to the surface of adjacent portions of the sidewall. 
     
     
         6 . The food container system of  claim 4 , wherein the draft angle of the first pair of sidewalls is different than the draft angle of a second pair of sidewalls identical sidewalls opposite one another, and the lug thickness of the lugs in the first pair of sidewalls is different than the lug thickness of the lugs in the second pair of sidewalls. 
     
     
         7 . The food container system of  claim 1 , wherein the nominal wall thickness of the sidewalls is between 0.6 mm and 0.7 mm. 
     
     
         8 . The food container system of  claim 1 , wherein each lug has a lateral width of between 0.2-0.5 inches. 
     
     
         9 . The food container system of  claim 1 , wherein the container floor defines a plurality of longitudinal troughs therein shaped to cradle cylindrical food items. 
     
     
         10 . The food container system of  claim 1 , wherein at least some of the lugs form a part of the floor. 
     
     
         11 . A food container system, including:
 a wet press molded container of solid continuous construction of fibrous material, the container having a floor and contiguous upstanding sidewalls angling outward at draft angles and upward to an upper lip, wherein the sidewalls have a plurality of spaced-apart lugs each of which projects in or out from an adjacent portion of the respective sidewall and has a lug thickness greater from a projecting surface to a base surface on an opposite face of the sidewall than a nominal wall thickness of the adjacent portion of the respective sidewall, the floor and sidewalls surrounding an inner cavity below the upper lip adapted to receive food, each lug being a rounded bulge having a thickness (t) of between 3-5 times the nominal wall thickness of the sidewalls and a lateral width of at least 0.2 inches and no more than 1 inch, wherein a first molded container may be stacked within a second molded container such that the lugs on the first container contact the inner surface of the second container at the location of the lugs on the second container and maintain a predetermined axial spacing between the first and second containers.   
     
     
         12 . The food container system of  claim 11 , wherein the container is rectangular and has four sidewalls, and wherein each of the sidewalls has two of the lugs spaced apart closer to adjacent corners than to each other. 
     
     
         13 . The food container system of  claim 11 , wherein the container is rectangular and has four sidewalls, and wherein each of the sidewalls has two of the lugs, and wherein a first pair of sidewalls opposite one another have lugs with inner surfaces which are contiguous and uninterrupted relative to the inner surface of adjacent portions of the sidewall. 
     
     
         14 . The food container system of  claim 13 , wherein a second pair of sidewalls opposite one another have lugs with inner surfaces which are indented or stepped relative to the inner surface of adjacent portions of the sidewall. 
     
     
         15 . The food container system of  claim 11 , wherein the container is rectangular and has four sidewalls, and wherein each of the sidewalls has two of the lugs, and wherein the draft angle of the first pair of sidewalls is different than the draft angle of a second pair of sidewalls identical sidewalls opposite one another, and the lug thickness of the lugs in the first pair of sidewalls is different than the lug thickness of the lugs in the second pair of sidewalls. 
     
     
         16 . The food container system of  claim 11 , wherein all of the lugs project outward, and all have inner base surfaces which are contiguous and uninterrupted relative to the surface of adjacent portions of the sidewall. 
     
     
         17 . The food container system of  claim 16 , wherein the nominal wall thickness of the sidewalls is between 0.6 mm and 0.7 mm. 
     
     
         18 . The food container system of  claim 16 , wherein each lug has a lateral width of between 0.2-0.5 inches. 
     
     
         19 . The food container system of  claim 11 , wherein the container floor defines a plurality of longitudinal troughs therein shaped to cradle cylindrical food items. 
     
     
         20 . The food container system of  claim 11 , wherein at least some of the lugs form a part of the floor, and at least some of the lugs are located along a corresponding sidewall vertically spaced from an associated upper lip portion.