# Patent

## Title
Dunnage structure made with multiple ply partitions

## Abstract

A dunnage structure comprising a partition matrix made up of folded partitions, each of the partitions having two plies fused together in select locations. The partitions may be made by folding a partition blank and securing a portion of the folded partition blank to itself in predetermined locations. Passages extend through portions of the partitions to allow multiple partitions to be secured together using connectors.

## Background
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 12/175,983 filed Jul. 18, 2008 entitled “Dunnage Structure Made With Multiple Ply Partitions”, which is fully incorporated by reference herein. U.S. patent application Ser. No. 12/175,983 is a continuation-in-part of U.S. patent application Ser. No. 12/013,002 filed Jan. 11, 2008, entitled “Partition Assembly Made With Multiple Ply Partitions”, which is fully incorporated by reference herein. U.S. patent application Ser. No. 12/013,002 is a continuation of U.S. patent application Ser. No. 11/036,809 filed Jan. 14, 2005, now U.S. Pat. No. 7,344,043, entitled “Partition Assembly Made With Multiple Ply Partitions”, which is fully incorporated by reference herein.


FIELD OF THE INVENTION
The present invention relates to a dunnage structure for dividing the space inside a container; more particularly to a multiple ply partition for use in such a dunnage structure.
BACKGROUND
In the storage, shipment or display of parts or merchandise, it is a common practice to divide the interior of a box or container into a plurality of individual cells. The interior of a box or container is typically separated by a series of dividers, one set of parallel dividers being orthogonal to a second set of dividers. The dividers separate the interior of the container into a plurality of individual holding cells each of which is intended to hold a separate item for display and/or shipment. The division of the interior of the box or container helps prevent the items therein from contacting one another and breaking during shipping. The division or partitioning of the container also aids in the loading and unloading of the items therein, as well as inventorying the contents of each box or container.
The dividers typically are slotted and arranged in an orthogonal relationship to divide the interior of the box or container into a desired number of holding cells. The dividers are slotted in a manner that enables the dividers to engage with one another at the location of the slots so that the dividers form an orthogonal grid or matrix. Typically the dividers are made of the same material as the material of the box or container, plastic or paperboard. However, the dividers may be constructed of any suitable material with sufficient rigidity to prevent the contents of the container from contacting one another and being damaged.
One disadvantage with known partition assemblies is that the upper edges of the partitions may have exposed sharp edges. For example, corrugated plastic partitions may have sharp upper edges created by cutting a sheet of corrugated plastic to the desired partition size. Such an exposed upper edge of the partition may damage products or parts being loaded into or unloaded from the cells of the container in which is located the partition matrix or assembly. Partition assemblies incorporating partitions having exposed sharp upper edges may require additional clearance between the parts being either loaded or unloaded and the upper edges of the partitions.
Another disadvantage of such partition assemblies is that the person loading or unloading parts or products into or from the cells of the container may cut or scrape their knuckles or hands on the exposed edges of the partitions when loading or unloading parts or products.
Additionally, the stiffness of the partitions of the assembly is dictated by the material from which the partitions are made. The stiffness of the partitions may not be altered without changing the material from which the partition is made.
U.S. Pat. No. 2,647,679 discloses a partition assembly which separates the interior of a box or container into a plurality of cells. The partitions of the assembly disclosed in this patent are formed by folding a blank of material along a fold line so as to create a rounded smooth upper edge. The material is disclosed as being paper board or similar material.
Another partition assembly for dividing the interior of a container is disclosed in U.S. Pat. No. 4,375,263. The partitions of this assembly are similarly rounded along their upper edges and are made of transparent vinyl sheets.
In each of these prior art partition assemblies, the opposed plies of the dividers or partitions formed by folding a blank of material are not secured to each other. Consequently, the opposed sides or plies of the partitions are not secured to each other and may be easily separate, thereby expanding into the cells of the container defined by the partition assembly. Consequently, the partitions may contact the products or parts stored in the cells and damage them. Additionally, the partition plies may easily tear or otherwise be damaged. Upon assembly or disassembly of the partition matrix, one or more portions of the partitions may tear and hence cause disassembly of at least a portion of the partition matrix.
It therefore has been one objective of the present invention to provide a double-ply partition for use in a dunnage structure in which the plies are secured together in predetermined locations and have passages for joining multiple partitions together.
It has been a further objective of the invention to provide a method of manufacturing a double-ply partition for use in a dunnage structure which is secure and may not be easily disassembled.
It has been another objective of the present invention to provide a double-ply partition for use in a dunnage structure in which the partition has the desired degree of stiffness.
SUMMARY OF THE INVENTION
The dunnage structure of the present invention which accomplishes these objectives comprises a plurality of two-ply partitions which are folded and secured together to form a plurality of holding cells into which different parts are stored for shipment or display. The partitions are joined together with a plurality of connectors which extend through passages of the partitions.
In one embodiment, each partition is formed of a multilayered material folded in half and secured to itself at select or predetermined locations. The fold creates a rounded edge at the fold line which is smooth and has a continuous surface with the outer side walls or skins of the partition. The partition comprises an inner layer of foam, preferably polyolefin foam, and an outer layer, skin or facegood. The opposed plies of the partition are fused or parent welded to each other at select or predetermined locations using only heat without any additional material required. Along the passages of the partition, the opposed plies are not secured to each other, allowing a connector to pass between the opposed plies of the partition. In this manner, the opposed plies of the partition are partially fused or joined together without any additional material such as glue.
In one embodiment, the inner foam layer is bonded directly or laminated to the outer layer. The outer layer may be made of woven polyester, non-woven polypropylene, foamed or solid polyolefin or other material such as latex or non-polyolefin plastic. The outer layer may be selected as appropriate to protect or prevent surface damage to the products being stored and/or shipped in the cells of the container.
In an alternative embodiment, a desired stiffness or rigidity may be created in the partition by inserting into the partition blank from which the partition is made a thin plastic skin or middle layer between the inner foam layer and the outer layer or facegood. By altering the thickness and/or mechanical properties of this middle layer, or by omitting it altogether, the desired level or degree of stiffness of the partition may be achieved during the manufacturing process.
In an alternative embodiment, the partition may be made solely of one foam layer without any outer layer or facegood.
The method of making a two-ply partition by securing select portions of opposed plies of the partition together is quick, easy and inexpensive. Portions of the opposed plies of the partition are permanently secured to each other, making the partition non-disassembling and enhanced by being double-layered or double-ply without using any additional material or tools. Other portions of the opposed plies of the partition are not permanently secured to each other and define passages adapted to receive and retain the connectors used to join together multiple partitions.
A dunnage structure incorporating one or more two-ply partitions having passages may be quickly and easily formed by passing multiple connectors through the passages of multiple folded partitions. The next step comprises securing opposed ends of the connectors to an anchor which may be a top of the dunnage structure or any similar type device or structure. A dunnage structure formed in such a manner may be used in a horizontal dispensing container or any other similar shipping container such as a metal rack, for example.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of dunnage structure of the present invention in an assembled condition;
FIG. 1A is a perspective view of the dunnage structure of FIG. 1 in a partially disassembled condition;
FIG. 2 is a perspective view of a blank used to form a folded partition for use in the dunnage structure of FIG. 1 with connectors;
FIG. 2A is a cross-sectional view taken along the line 2A-2A of FIG. 2;
FIG. 2B is a cross-sectional view of an alternative embodiment of a portion of a partition used in accordance with the present invention having a middle layer;
FIG. 2C is a perspective view of a tray created by folding and stapling the partition of FIG. 2;
FIG. 3 is a perspective view of another two-ply partition used to form a dunnage structure like that of FIG. 1 with connectors;
FIG. 3A is a perspective view of another tray created by folding and stapling the partition of FIG. 3;
FIG. 3B is a rear perspective view of the tray of FIG. 3A;
FIG. 4 is a perspective view of another dunnage structure built in accordance with the present invention in a partially disassembled condition;
FIG. 5 is a perspective view of another two-ply partition used to form a dunnage structure like that of FIG. 6 with connectors;
FIG. 5A is a cross-sectional view taken along the line 5A-5A of FIG. 5;
FIG. 5B is a cross-sectional view of an alternative embodiment of a portion of a partition;
FIG. 5C is a perspective view of a tray created by folding the partition of FIG. 5;
FIG. 6 is a perspective view of another dunnage structure built in accordance with the present invention in a partially disassembled condition;
FIG. 7 is a perspective view of one embodiment of dunnage structure for use in a container;
FIG. 8 is a perspective view illustrating the dunnage structure of FIG. 7 secured inside a metal rack;
FIG. 9 is a perspective view illustrating the dunnage structure of FIG. 7 secured inside a different metal rack than the metal rack of FIG. 8;
FIG. 10 is a perspective view of one embodiment of dunnage structure of the present invention in an assembled condition located inside a horizontal dispensing container, the top being shown disassembled;
FIG. 11 a perspective view of the horizontal dispensing container of FIG. 10 with a dunnage structure inside and fully assembled;
FIG. 12 is a perspective view of another embodiment of dunnage structure in an assembled condition;
FIG. 12A is a perspective view of the dunnage structure of FIG. 12 in a partially disassembled condition;
FIG. 13 is a cross-sectional view of a portion of the dunnage structure of FIG. 12.



DETAILED DESCRIPTION OF THE DRAWINGS
Referring to the drawings and particularly to FIG. 1, there is illustrated a dunnage structure 10 for dividing the space inside a container. The dunnage structure 10 may be used in any container and in particular, any horizontal dispensing container including a metal rack like the ones shown in FIGS. 5 and 6. Alternatively, the dunnage structure may be used in a container known in the industry as a Redi-Rack® shown in FIGS. 10 and 11. The present invention is not intended to be limited for use in any one style or type of container.
As illustrated in FIG. 1, one embodiment of dunnage structure 10 comprises a plurality of partition trays 14 joined together with connectors 16 and a top 18. For purposes of this document, the term “tray” is not intended to be limited to any dictionary definition or the exact “tray” shown in the drawings. The term “tray” is intended to mean any partition folded and formed into a structure having a bottom and two opposed side walls. Similarly, the term “dunnage structure” is not intended to be limited to any embodiment shown or described herein, but rather is intended to mean any number of pieces or parts held or put together for separating and protecting products for shipment.
As shown in FIG. 2, in one embodiment, each tray 14 is formed from a two-ply partition 20 having a rounded front edge 22. As shown in FIG. 2, the partition 20 has a middle portion 24 and two opposed side portions 26, the middle portion 24 being separated from the side portions 26 by parallel fold lines 28. The partition 20 has a generally rectangular rear portion 30 separated from the remainder of the middle portion 24 by a fold line 32. The partition 20 has additional fold lines 34 which may be omitted, if desired. Two aligned slots 38 are aligned with fold lines 34. Each slot 38 extends through the partition 20. Two generally triangular locking portions 36 are located behind the slots 38 and fold lines 34, as shown in FIG. 2. The partition 20 may be other shapes or sizes and is not intended to be limited to the configuration shown in FIG. 2. For example, the locking portions 36 may be rectangular rather than triangular.
As shown in FIG. 2, the partition 20 has a first passage 40 through the rear portion 30 of the partition 20 and second and third passages 42, 44, each extending through middle and side portions 24, 26 of the partition 20, respectively. Although the drawings show the partition 20 having three parallel passages 40, 42 and 44, the partition 20 may have any number of passages of any desired width in any desired location.
FIG. 2 shows a first connector 46 extending through the first passage 40 and beyond the opposed side edges 48 of the rear portion 30 of partition 20. In the illustrated embodiment, the first connector 46 extending through the first passage 40 is generally parallel the front and rear edges 22, 50 of the partition 20. FIG. 2 further shows a second connector 52 entering second passage 42. When fully extending through the second passage 42, the second connector 52 extends beyond the opposed outer side edges 54 of the side portions 26 of partition 20. Lastly, FIG. 2 shows the third connector 56 extending through third passage 44 and extending beyond the outer edges 54 of the partition 20.
The connectors 16 in any of the embodiments may be made of plastic, such as polyvinyl chloride, high density polyethylene or nylon. However, any other suitable materials, such as metal, may be used in the connectors. The connectors may be any desired shape, width or length, depending upon the application.
In order to make the tray 14 shown in FIG. 2C from the partition 20 shown in FIG. 2, the partition 20 is folded along fold lines 28 and 32. The first connector 46 is passed through the slots 38 and wrapped around the outer surfaces 58 of the side portions 26 of the partition 20, which are now in a vertical orientation as shown in FIG. 2C. The ends 60 of the first connector 46 are fastened with fasteners such as staples 62 to the side portions 26 of the partition 20. The rear portion 30 of the partition 20 is now vertically oriented and becomes a rear wall of the assembled tray 14. Similarly, the side portions 26 of the partition 20 are now vertically oriented and become the side walls of the tray 14. The middle portion 24 of the partition 20 becomes the bottom of the tray 14. The tray 14 has an open front 64 with a rounded front edge 22, as shown in FIG. 2C. The rounded front edge 22 of each tray 14 prevents scratches, cuts and abrasions when workers insert or remove parts or products from cells 76 of the dunnage structure 10.
As shown in FIG. 1A, in the lower tray of each column 66 of trays, the second connector 52, which is longer than the second passage 42, extends downwardly along one side wall 26, along the bottom 24 of the tray 14 and up along the opposed side wall 26, through second passage 42. Similarly, the third connector 56, which is longer than the third passage 44, extends downwardly along one side wall 26, along the bottom 24 of the tray 14 and up along the opposed side wall 26, through third passage 44.
In order to make dunnage structure 10, a plurality of trays 14 are secured together using multiple connectors 16. More specifically, the second and third connectors 52, 56 extend through passages in multiple stacked partitions in a column and function to align and connect these trays 14 together. More specifically, second connector 52 extends through the entire second passage 42 of the lowermost or bottom tray 14 of column 66 of trays 14, i.e., along the bottom 24 and side walls 26 of the bottom tray 14. The second connector 52 also extends through the side walls 26 only (not the bottom 24) of the middle and upper trays 14 of column 66. As shown in FIGS. 1 and 1A, second connector 52 is of such a length that end portions 69 thereof are passed through openings or slots 68 in the top 18 of the dunnage structure 10 and secured to the top 18 with fasteners 70.
Similarly, third connector 56 extends through the entire third passage 44 of the lowermost or bottom tray 14 of column 66 of trays 14, i.e., along the bottom 24 and side walls 26 of the bottom tray 14. The third connector 56 also extends through the side walls 26 only (not the bottom 24) of the middle and upper trays 14 of column 66. The third connector 56 is of such a length that end portions 72 thereof are passed through openings or slots 74 in the top 18 of the dunnage structure 10 and secured to the top 18 with fasteners 70. See FIG. 1.
The top 18 comprises a generally planar main portion 19 and two side portions 21 extending downwardly from the edges 23 of the main portion 19. Although one configuration of top is illustrated, other configurations or styles of tops may be used without departing from the spirit of the invention. The top may be equipped with other devices or structure which anchor or secure the end portions of the connectors and consequently allow the trays to hang or suspend from the top of dunnage structure. Alternatively, the top may be omitted and the connectors 16 secured to one or more portions or components of the container in which the dunnage structure 10 is housed or located.
Although FIGS. 1 and 1A show two connectors 52, 56 being used to secure together three aligned trays 14 in a vertically oriented column 66, three such columns 66 being used in dunnage structure 10, any number of connectors may be used to secure together any number of trays in a column. Similarly, the dunnage structure may have any desired number of columns of any desired height. Adjacent columns may be secured together or not. Dunnage structure 10 is shown in FIG. 1 as having three horizontally extending rows 96 of holding cells 76 across the dunnage structure 10.
The trays 14 of the dunnage structure 10 may be the same size as shown in FIGS. 1 and 1A in order that the individual holding cells 76 of the dunnage structure 10 are evenly sized. Alternatively, the trays 14 of the dunnage structure 10 may be sized differently in order to form holding cells 76 of the dunnage structure of differing sizes to accept different sized parts or products.
In one embodiment of the present invention, each of the partitions 20 is made of a multilayered material. Each of the partitions 20 is a two-ply partition which may be at least partially formed by one of the methods shown and described in U.S. Pat. No. 7,344,043, which is fully incorporated herein. FIG. 2A illustrates one of the partitions 20 in detail according to one embodiment of the present invention. As best illustrated in FIG. 2A, partition 20 has two opposed plies 78 and 80 which are parallel to one another and joined together in select or predetermined locations (outside or external of passages 16). The partition 20 has an outer layer or skin 82 assuming a generally inverted U-shaped configuration when the partition 20 is folded and the opposed plies 78 and 80 at least partially secured together. A wide variety of materials may be used for the outer layer or skin 82 including, but not limited to, woven polyesters, non-woven polypropylenes, foamed and solid polyolefins, latex, non-polyolefin plastics.
In the embodiment shown in FIG. 2A, inside the outer layer or skin 82 is a foam interior 84 comprising two layers 86, 88 joined together along interior surfaces 90. A wide variety of materials may be used for the foam interior 84 of the partition 20. In one preferred embodiment, the foam interior 84 is a polyolefin foam. However, other materials other than foam which may be welded or joined together may be used in accordance with the present invention. If desired, the outer skin 82 may be omitted, in which case, the entire partition 20 would be made of foam. FIG. 2A illustrates in cross-section the third passage 44 shown in FIG. 2 of partition 20. In this third passage 44, as in any of the passages 16 of the partitions 20, the adjoining layers 86, 88 of the foam interior 84 are not secured together, but instead are separable to allow a connector such as third connector 56 to pass between the adjoining layers 86, 88 of the foam interior 84. In one or more selected or predetermined areas outside the passages 16, the adjoining layers 86, 88 of the foam interior are fused or parent welded together.
FIG. 2B illustrates an alternative embodiment of two-ply partition 20a. In this embodiment, partition 20a has an additional layer incorporated therein when compared to the partition 20 shown in FIG. 2A. In this alternative embodiment, the partition 20a has an outer layer or skin 82a, a foam interior 84a comprising two layers 86a, 88a joined together along surfaces 90a. In addition, a middle stiffening layer 92 is secured between the outer layer or skin 82a and the foam interior 84a. Like the outer layer 82a of the partition 20a, the middle stiffening layer 92 assumes a generally inverted U-shaped configuration when the partition 20a is folded and the opposed plies 78a and 80a at least partially secured together, as shown in FIG. 2B. A wide variety of materials may be used for the middle stiffening layer or skin 92 including, but not limited to, various plastics. If desired, additional middle stiffening layers of any suitable material (not shown) may be added to the partition. The partition 20a has a smooth edge 22a like the partition 20 shown in FIG. 2A created by the folding of a partition blank (not shown) and securing the opposed plies 78a, 80a together in select locations.
FIGS. 3, 3A and 38 illustrate an alternative embodiment of partition 20b which is used to form a tray 14b. Each tray 14b, shown in FIGS. 3A and 3B is formed from a two-ply partition 20b having a rounded front edge 22b. The partition 20b has a middle portion 24b and two opposed side portions 26b, the middle portion 24b being separated from the side portions 26b by parallel fold lines 28b. The partition 20b has a generally rectangular rear portion 30b separated from the remainder of the middle portion 24b by a fold line 32b. The partition 20b has two additional fold lines 34b which separate two generally triangular locking portions 36b from the remainder of the side portions 26b, as shown in FIG. 3.
As shown in FIG. 3, the partition 20b has no passage through the rear portion 30b of the partition 20b. Instead, partition 20b has a first passage 42b extending through middle and side portions 24b, 26b, respectively, and a second passage 44b extending through middle and side portions 24b, 26b, respectively. Although the drawings show the partition 20b having two parallel passages 42b and 44b, the partition 20b may have any number of passages in any desired locations.
FIG. 3 shows a first connector 52b entering first passage 42. When fully inserted into the passage 42, the first connector 52b extends beyond the opposed outer side edges 54b of the side portions 26b of partition 20b. FIG. 3 further shows a second connector 56b extending through second passage 42b and beyond the opposed outer side edges 54b of the side portions 26b of partition 20b. 
In order to make the tray 14b shown in FIGS. 3A and 3B from the partition 20b shown in FIG. 3, the partition 20b is folded along fold lines 28b, 32b and 34b. The rear portion 30b is folded along fold line 32b into a vertical position or orientation. The locking portions 36b are then wrapped around the outer surface of the rear portion 30b of the partition 20b and secured thereto with fasteners 94, as shown in FIG. 3B. The side portions 26b are folded along fold lines 28b into a vertical orientation as shown in FIG. 3A. The rear portion 30b of the partition 20b is now vertically oriented and becomes the rear wall of the tray 14b. Similarly, the side portions 26b of the partition 20b are now vertically oriented and become the side walls of the tray 14b. The middle portion 24b of the partition 20b becomes the bottom of the tray 14b. The tray 14b has an open front 64b with a rounded front edge 22b as shown in FIG. 3A. The rounded front edge 22b of each tray 14b prevents scratches, cuts and abrasions when workers insert or remove parts or products from cells of the dunnage structure. In addition, the rounded front edge 22b of each tray 14b aids the insertion and removal of part or products from the cells of the dunnage structure.
FIG. 4 illustrates an alternative dunnage structure 10b for use in a horizontal dispensing container open on opposed sides. Dunnage structure 10b comprises two sides of dunnage 61, 63, each side comprising three columns 66b of trays 14b, each column 66b comprising three trays 14b. Therefore, the dunnage structure 10b comprises nine holding cells 76b on each side 61 and 63, three across in a row 96b and three down in each column 66b. In total, this dunnage structure 10b has eighteen cells 76b, all of which may be filled with product for shipment. As shown in FIG. 4, the back or rear walls 30b of the trays 14b of one side 61 abut and are joined in any known manner to the back or rear walls 30b of the trays 14b of the other side 63 of the dunnage structure 10b. Although FIG. 4 shows clips 65 joining the back walls 30b of trays 14b, any other fastening device, such as rivets or welds, may be used.
Although the dunnage structure 10b is illustrated being constructed of trays 10b, as shown in detail in FIGS. 3, 3A and 3B, the dunnage structure 10b may be created using other trays, similar to trays 14, shown in detail in FIGS. 2 and 2A. Any of the two-ply partitions having passages described herein may be used in any of the dunnage structures shown or described herein.
Dunnage structure 10b further comprises a top 18b, like top 18, having a generally planar main portion 19b and two side portions 21b extending downwardly from the edges 23b of the main portion 19b. The top 18b has slots 73 sized so that the tops of the connectors 52b, 56b may pass therethrough and be secured to the top 18b. Although one configuration of top is illustrated, other configurations or styles of tops may be used without departing from the spirit of the invention. Any structure which forms part of the container may be used to retain or hold the top end portions of the connectors 16, in which case the top may be omitted from the dunnage structure.
FIGS. 5, 5A and 5C illustrate an alternative embodiment of partition 20c, which is used to form a tray 14c open on opposite ends. Each tray 14c, shown in FIG. 5C, is formed from a two-ply partition 20c having a rounded front edge 22c. As shown in FIG. 5, partition 20c has a middle portion 24c and two opposed side portions 26c, the middle portion 24c being separated from the side portions 26c by parallel fold lines 28c. 
As shown in FIG. 5, the partition 20c has no rear portion and therefore, when folded along fold lines 28c, forms tray 14c having opposed open ends 64c. As shown in FIG. 5, partition 20c has parallel first and second passages 42c, 44c extending through middle and side portions 24c, 26c of partition 20c. Although the drawings show the partition 20c having two parallel passages 42c and 44c, the partition 20c may have any number of passages in any desired locations extending in any desired direction. This applies to any of the partitions shown or described herein.
FIG. 5 shows a first connector 52c entering first passage 42c. When fully inserted into the passage 42c, the first connector 52c extends beyond the opposed outer side edges 54c of the side portions 26c of partition 20c. FIG. 5 further shows a second connector 56c extending through second passage 42c and beyond the opposed outer side edges 54c of the side portions 26c of partition 20c. Although passages 42c, 44cc are illustrated extending longitudinally perpendicular to the fold lines 28c, it is within the scope of the present invention that the passages extend transversely parallel the fold lines 28c in certain applications or structures. This applies to any of the partitions and dunnage structures described or illustrated herein.
In order to make tray 14c shown in FIG. 5C from the partition 20c shown in FIG. 5, partition 20c is folded along fold lines 28c to bring the side portions 26c into a vertical orientation. The side portions 26c of partition 20c become vertically oriented side walls of the tray 14c when the tray is joined to other trays. The middle portion 24c of the partition 20c becomes the bottom of the tray 14c. The tray 14c has two opposed open ends 64c with a rounded front edge 22c at one end as shown in FIG. 5C. Alternatively, each open end 64 may have a rounded front edge. The rounded front edge 22c of each tray 14c prevents scratches, cuts and abrasions when workers insert or remove parts or products from cells of the dunnage structure. In addition, the rounded front edge 22c of each tray 14c aids the insertion and removal of part or products from the cells of the dunnage structure 10c. 
FIG. 5B illustrates a portion of an alternative embodiment of two-ply partition 20d. In this embodiment, partition 20d comprises two dissimilar materials fused or parent welded to each other in select or predetermined locations 90d beside the passages (only one 44d being shown in FIG. 5B) of the partition. In this alternative embodiment, the partition 20d has an outer layer or skin 82d on both sides of the partition 20d, a foam interior 84d comprising two dissimilar layers 86d, 88d fused or parent welded together along surfaces 90d beside the passages of the partition. The opposed plies 78d and 80d of the foam interior 84d are at least partially secured together along surfaces 90d, as shown in FIG. 5B. If desired, additional middle stiffening layers of any suitable material (not shown) may be added to the partition 20d. The partition 20d lacks a smooth edge, but instead has a blunt edge 5 at the front thereof. This concept of making a partition by fusing or parent welding different materials may be used in any of the partitions or any of the dunnage structures contemplated or described or shown herein.
FIG. 6 illustrates an alternative dunnage structure 10c comprising three columns 66c of trays 14c, each column 66c comprising three trays 14c. Therefore, the dunnage structure 10c comprises nine holding cells 76c, three across in a row 96c and three down in each column 66c. Although the dunnage structure 10c is illustrated being constructed of multiple identical trays 14c, as shown in detail in FIG. 5C, the dunnage structure 10c, or any dunnage structure described herein, may be created using trays of different sizes or shapes suited to ship a particular part or product. Any of the two-ply partitions having passages described herein may be used in any of the dunnage structures shown or described herein, such as dunnage structure 10c having opposed open ends for use in a container open on opposed sides.
Dunnage structure 10c further comprises a top 18c having a generally planar main portion 19c and two side portions 21c extending downwardly from the edges 23c of the main portion 19c. Although one configuration of top is illustrated, other configurations or styles of tops may be used without departing from the spirit of the invention.
As shown in FIG. 6, second and third connectors 52c, 56c are each of such a length that end portions 69c, 72c thereof may be passed through openings or slots 73c in the top 18c of the dunnage structure 10c and secured to the top 18c with fasteners (not shown). Any structure which forms part of the container may be used to retain or hold the top end portions of the connectors 16, in which case the top may be omitted from the dunnage structure.
FIG. 7 illustrates an alternative dunnage structure 10d comprising three columns 66d of trays 14d, each column 66d comprising three trays 14d. Therefore, the dunnage structure 10d comprises nine holding cells 76d, three across in a row 96d and three down in each column 66d. Although the dunnage structure 10d is illustrated being constructed of multiple identical trays 14d, the dunnage structure 10d may be created using trays of different sizes or shapes suited to ship a particular part or product.
As shown in FIG. 7, dunnage structure 10d further comprises a top 18d having a generally planar main portion 19d and two side portions 21d extending downwardly from the edges 23d of the main portion 19d. Although one configuration of top is illustrated, other configurations or styles of tops may be used without departing from the spirit of the invention. The top 18b has slots 73 sized so that the tops of the connectors 52b, 56b may pass therethrough and be secured to the top 18b. Although one configuration of top is illustrated, other configurations or styles of tops may be used without departing from the spirit of the invention.
As shown in FIG. 7, dunnage structure 10d further comprises three different sets of first and second connectors 52d, 56d, each set of connectors 52d, 56d supporting one column 66d of three trays 14d. However, rather than being secured to the top 18d with fasteners, the end portions 69d, 72d of connectors 52d, 56d, respectively, each have holes 98 therein through which a locking member 100 passes. Although the locking member 100 is shown as being a bar having a circular cross-section, any other suitable locking member may be used to keep the first and second connectors 52d, 56d from falling downwardly through the passages of the trays 14d. This method of using a locking member to pass through portions of the connectors may be used in any of the embodiments of dunnage structure contemplated by the present invention including those described or shown herein.
Dunnage structure 10d may be secured in metal rack 12 using several different methods, one of which is shown in FIG. 8. Referring to FIG. 8, the rack 12 may have grooves 104 therein. End portions 102 of each locking member 100 may be aligned and engaged with grooves 104. This locking assembly of grooves 104 and locking member 100 retains the dunnage structure 10d in place inside the interior of metal rack 12 or any other suitable container.
Another method of securing dunnage structure 10d in a metal rack is shown in FIG. 9. This rack 13, rather than having grooves 104, like the rack 12 shown in FIG. 8, has holes 106 in the upper side bars 108. The end portions 102 of each locking member 100 fit inside the holes 106 in the upper side bars 108 of rack 13. The locking members 100 support the dunnage structure 10d inside the rack 13.
FIG. 10 illustrates an alternative embodiment of dunnage structure 10e comprising six columns 66e and four rows 96e of cells 76e inside a container 122. The dunnage structure 10e comprises a plurality of trays 14 as described above joined together with first and second connectors 52e and 56e. The end portions 69e, 72e of the connectors 52e, 56e, respectively, are each overlapped and secured together to form a loop 110. Locking members 112 are passed through the loops 110. End portions 114 of the locking members 112 are secured inside grooves 116 formed in the front and rear braces 118, 120, respectively, of container 122. This container is described in detail in U.S. Pat. No. 7,360,663, which is fully incorporated herein. However, this method of forming loops in the connectors may be used in any dunnage structure along with the concept of passing locking members through the connector loops, the locking members being engaged with the container and supporting the dunnage structure.
FIG. 11 illustrates the container 122 of FIG. 10 in an assembled condition. The dunnage structure 10e is covered in the front of the container 122 with a cover 124, using any method or structure known in the industry.
FIGS. 12, 12A and 13 illustrate an alternative dunnage structure 10f comprising three columns 66f of trays 14f having rounded front edges 22f, each column 66f comprising three trays 14f. Therefore, the dunnage structure 10f comprises nine holding cells 76f, three across in a row 96f and three down in each column 66f. Although the dunnage structure 10f is illustrated being constructed of multiple identical trays 14f, like tray 14b shown in detail in FIG. 3A, the dunnage structure 10f, or any dunnage structure described herein, may be created using trays of different sizes or shapes suited to ship a particular part or product. Any of the two-ply partitions having passages described herein may be used in any of the dunnage structures shown or described herein, such as dunnage structure 10c having opposed open ends for use in a container open on opposed sides. Thus, dunnage structure 10f may comprise multiple trays 14c shown in FIG. 5C or multiple trays 14b shown in FIG. 3B or any other tray within the description or scope of the present inventions.
As best shown in FIG. 12A, dunnage structure 10f further comprises a top 18f having a generally planar main portion 19f and two side portions 21f extending downwardly from the edges 23f of the main portion 19f. Although one configuration of top is illustrated, other configurations or styles of tops may be used without departing from the spirit of the invention.
As shown in FIGS. 12, 12A and 13, each tray 14f has connectors 16f of such a length that each connector 16f has two opposed end portions 128 which extend beyond the passageways 42f 44f, respectively, of the tray 14f. In the uppermost row of trays 14f, end portions 128 of connectors 16f thereof may be passed through openings or slots 126 in the top 18f of the dunnage structure 10f and secured to the top 18f with fasteners 70f, as shown in FIG. 12. Any structure which forms part of the container may be used to retain or hold the top end portions of the connectors, in which case the top may be omitted from the dunnage structure.
In order to make dunnage structure 10f, a plurality of trays 14f are secured together using multiple connectors 16f. More specifically, each of the connectors 16f of each of the trays 14f, except the trays 14f of the uppermost row 96f of trays 14f adjacent the top 18f, extends through one of the passages 42f, 44f in one of the partitions or trays and is secured to an adjacent upper tray 14f or the top 18f of the dunnage structure 10f. Thus, the connectors 16f of trays 14f function to align and connect these trays 14f together. Each of the connectors 16f extends through a passage 42f, 44f of one of the trays 14f, i.e., along the bottom 24f and side walls 26f of the tray 14f and is secured to an adjacent upper tray 14f or the top 18f of the dunnage structure 10f. More specifically, the end portions 128 of connectors 16f are secured, such as with staples 130 or any other fasteners, to the exterior of the adjacent tray 14f above it or to the top 18f. As shown in FIGS. 12 and 12A, connectors 16f are of such a length that end portions 128 thereof are passed through openings or slots 126 in the top 18f of the dunnage structure 10f and secured to the top 18f with fasteners 70f. 
Any top illustrated or described herein may be equipped with other devices or structure which anchor or secure the end portions of the connectors and consequently allow the trays to hang or suspend from the top of dunnage structure. Alternatively, the top may be omitted and the connectors 16f secured to one or more portions or components of the container in which the dunnage structure 10f is housed or located.
While we have described only a few embodiments of our invention, we do not intend to be limited except by the scope of the following claims.

## Claims

1. A dunnage structure comprising:
a plurality of two-ply partitions folded into trays having open fronts, each of said partitions having a middle portion and two opposed side portions which become a horizontally oriented bottom and vertically oriented sidewalls of the tray, respectively, the middle portion being separated from the side portions by parallel fold lines, each of the partitions having a pair of passages extending through the middle and side portions and comprising opposed plies fused together at select locations; and
each of said trays having connectors extending through the passages of the partitions and being secured to another tray or a top of the dunnage structure.

2. The dunnage structure of claim 1 wherein each of said partitions has a foam interior portion.

3. The dunnage structure of claim 2 wherein said foam interior portion is polyolefin foam.

4. The dunnage structure of claim 1 wherein each of said partitions has a rounded edge.

5. The dunnage structure of claim 1 wherein each of said partitions has a foam interior portion and an outer skin.

6. A dunnage structure comprising:
a plurality of partitions, each of said partitions having a rounded edge and comprising opposed plies at least partially parent welded together, each of said partition having passages extending therethrough, each of said partitions being folded into a tray having a horizontally oriented bottom and two sidewalls extending upwardly from said bottom; and
connectors extending through portions of the passages of the partitions, joining adjacent trays together.

7. The dunnage structure of claim 6, at least one of said partitions having a foam interior portion and an outer skin secured to said foam interior portion.

8. The dunnage structure of claim 7 wherein said foam interior portion is two-ply.

9. The dunnage structure of claim 6 wherein said at least one of said partitions is formed by folding a partition blank and securing opposed plies of the partition blank together.

10. The dunnage structure of claim 6 wherein said partitions are made from the same material.

11. A dunnage structure comprising:
a plurality of partitions, each of the partitions being folded into a tray having a bottom, two sidewalls extending upwardly from said bottom and a rear wall extending upwardly from said bottom, each of said partitions having a rounded front edge and comprising opposed plies at least partially fused together and an outer face surrounding a foam interior, said partition having passages extending through the partition; and
connectors extending through portions of the passages of the partitions, joining adjacent trays together.

12. The dunnage structure of claim 11 wherein said outer face of each of said partitions comprises a woven polyester.

13. The dunnage structure of claim 11 wherein said foam interior is polyolefin foam.

14. The dunnage structure of claim 11 wherein each of said partitions is formed by folding a partition blank and securing a portion of the partition blank to itself.

15. A dunnage structure comprising:
a plurality of trays arranged in columns, each of the trays having a bottom and two sidewalls extending upwardly from said bottom, each of said trays having a rounded front edge and being made by folding a partition comprising opposed foam plies at least partially fused together and an outer skin, said tray having passages extending along the bottom and sides of the tray; and
generally U-shaped connectors extending through portions of the passages of the trays and having ends secured to an anchor, the connectors joining adjacent trays together.

16. The dunnage structure of claim 15 wherein said outer skin of each of said partitions comprises a woven polyester.

17. The dunnage structure of claim 15 wherein said foam is polyolefin foam.

18. The dunnage structure of claim 15 wherein each of said trays is formed by folding a partition blank and securing a portion of the partition blank to itself.