Patent Publication Number: US-9409706-B2

Title: Container having padded dunnage supports and L-shaped tracks

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 14/067,452 filed Oct. 30, 2013 entitled “Container Having Metal Rack, Padded Dunnage Supports and L-Shaped Tracks” now U.S. Pat. No. 9,051,113, which is a continuation-in-part of U.S. patent application Ser. No. 14/038,921 filed Sep. 27, 2013 entitled “Container Having Padded Dunnage Supports and L-Shaped Tracks” now U.S. Pat. No. 9,051,112. Each of these applications is fully incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to containers for use in shipping and, more particularly, to containers with movable members for supporting product. 
     BACKGROUND OF THE INVENTION 
     A large number of different container structures are utilized by manufacturers to ship a variety of different products to end users, which may be, for example, assembly plants. In the automobile industry, for example, an assembly plant assembling a particular automobile might utilize a number of different parts from different manufacturers. These manufacturers ship their respective parts to the assembly plant in container structures where the parts are then removed from dunnage or support members inside the container structure and assembled into a finished automobile. 
     Access to the product in the containers is of particular concern. Specifically, in the automotive industry, the containers full of product are positioned on an assembly line adjacent to a work area, which is associated with a particular product to be installed on a manufactured vehicle. For example, a container full of interior door panels is usually positioned next to a particular station on an assembly line where interior door panels are installed so that a line worker may easily access the door panels inside the container. The product or part is taken directly from the container and used on the line. Some existing containers are difficult to access, which makes removal of the parts therein difficult and time-consuming. For example, some containers are configured so that a line worker must walk around the container to remove parts or products from opposite ends of the container. As may be appreciated, a line worker only has a certain amount of time to install a part. Any delay in access and removal of the part from the container is undesirable. 
     In many containers, a line worker or employee must insert or remove parts from a distal or rear part of the container. The size and/or weight of the parts or workpieces may cause stress or strain on the line worker and, more particularly, on the back of the worker when inserting or removing parts from such a container. Such ergonomically unfriendly movements may cause physical trauma, pain and other injuries that may lead to lost production time. 
     In some situations, in order to alleviate such stress and/or strain on his or her body, the line worker may move to the rear or opposite end of the container to remove parts from inside the container. This requires space around the container which may not be available, depending on the physical layout of the plant or facility. The length (front to back) of certain containers may be limited because the container manufacturer needs to eliminate the need for a line worker to walk around the container to remove product from inside the container. Such containers having a reduced length reduce the number of parts or products which may be shipped and/or stored in the container. The more containers needed to ship a predetermined number of parts, the greater the cost to the shipper. 
     In other containers, a line worker or employee must lean forward and bend down into the container to insert or remove a part or workpiece from a lower portion of the container. This movement by the line worker is ergonomically unfriendly because the line worker must lean forward and bend down and lift a part or workpiece up and over a wall into the container to remove the part or workpiece from inside the container. Similarly, when a part or workpiece must be inserted into a container, the line worker may have to lean forward and insert the part, which may be heavy, into its proper location inside the container, again experiencing ergonomically unfriendly movements. Such movements may be necessary with many top loading containers and/or containers having multiple layers or levels of parts. 
     Depending upon the number of times the line worker repeats this unnatural motion into the interior of the container, strain in the back, legs and arms may result. The size and/or weight of the parts or workpieces may increase the strain on the line worker. Thus, simply removing multiple parts during a work day may cause physical trauma, pain and other injuries that may lead to lost production time. 
     Accordingly, there is a need for a container which prevents employees from walking around the container to insert or remove product from inside the container. 
     There is further a need for a container which prevents employees from having to perform difficult or straining repetitive reaching motions. 
     There is further a need for a container which brings product into an ergonomically friendly area or zone for insertion or removal of the product. 
     SUMMARY OF THE INVENTION 
     The present invention provides a container for holding product therein during shipment. The container comprises a base and two opposed sides. The base and sides may be part of a metal frame or part of a plastic pallet box. In one embodiment, at least one of the tracks on each side may be non-linear. For purposes of this document, a non-linear track includes, but is not limited to, a generally L-shaped track and/or a generally C-shaped track and/or a generally J-shaped track and/or a generally U-shaped track. In one embodiment, the container has one non-linear track on each side of the container. However, any number of non-linear tracks may be supported by each side of the container. 
     Each of the generally L-shaped tracks comprises a generally horizontally oriented portion and a generally vertically oriented portion. The generally vertically oriented portion extends downwardly from the generally horizontally oriented portion. 
     The container further comprises a plurality of movable padded dunnage supports supported by the tracks. Each padded dunnage support extends between opposed tracks at the same layer or level. For purposes of this document, the term “padded dunnage support” may be a unitary member or multiple components secured together in an assembly. For example, a “padded dunnage support” may comprise in combination a middle member and a pair of end members secured to opposed ends of the middle member along with a cushioning member at least partially surrounding a portion thereof. The end members may move inside or along stationary tracks or track assemblies like those disclosed in U.S. patent application Ser. No. 13/896,675, which is fully incorporated by reference herein. Alternatively, a “padded dunnage support” may comprise a unitary member like those disclosed in U.S. patent application Ser. No. 13/225,835, which is fully incorporated by reference herein, surrounded at least partially by a cushioning member. 
     For purposes of the present invention, the term “track” may be a unitary member or multiple components secured together. The present invention is not intended to be limited to the tracks like those illustrated and described herein. For example, a “track” may comprise a rail attached to one or more walls of a container. The term “track” is intended to include any number of stationary objects along which dunnage supports, as defined and/or illustrated herein, may slide or move during the loading or unloading of product from dunnage inside the container. 
     The container further comprises dunnage supported by the padded dunnage supports. The dunnage may be pouches or any other known dunnage made of textile fabric or any other known material. The dunnage may be secured to the padded dunnage supports in any known manner, such as sewing or welding. 
     According to another aspect of the present invention, the container has a base and opposed sides. The base and sides may be part of a metal frame or part of a plastic pallet box. The container further comprises at least one non-linear track supported by each of the opposed sides of the container. In one embodiment, each of the non-linear tracks is generally L-shaped. A plurality of movable padded dunnage supports extend between opposed tracks and move along corresponding tracks. In some embodiments, each of the padded dunnage supports comprises a pair of end members movable along the tracks and a middle member extending between the end members, the middle member being secured to each end member and being at least partially surrounded by a cushioning “noodle” or member. Each of the padded dunnage supports comprises an outer cushion or padding layer to protect products being stored or shipped in the dunnage. Pouches may be wrapped around the padded dunnage supports and supported by the padded dunnage supports. 
     The container may be adapted so that an operator located at the front of the container may pull product to be emptied from the rear of the container forwardly to a more ergonomically friendly position after products suspended from dunnage at the front of the container have been unloaded or removed. Thus, a person unloading the container from the front or proximal location of the container will not have to stretch or reach to the back of the container to unload remaining product. 
     Similarly, a person loading the container from the front of the container need not stretch or reach to the back of the container to insert or load product into the container. The loader of the container may push the padded dunnage supports and associated dunnage loaded with product rearwardly and load additional product in a more ergonomically friendly position or manner. For example, after product is loaded into dunnage suspended by adjacent padded dunnage supports, these padded dunnage supports and associated dunnage are pushed rearwardly to enable the loader to load additional product. Thus, the container allows product to be more efficiently and safely removed from the container or inserted therein without unnecessary stress or strain on the operator. 
     The end members of the padded dunnage supports may be made of plastic or any other desired material. Each side of the container has at least one non-linear track along which the padded dunnage supports move to move dunnage supported by the padded dunnage supports closer to the user for loading or unloading product. Each end member may have at least one head located inside the interior of the track so the end member remains engaged with the track. The end member may have another head outside the track for preventing the dunnage material from entering the interior of the track. 
     The tracks may have openings therein and removable caps for covering and/or closing the openings. If one or more of the padded dunnage supports needs to be removed or inserted, a person may remove and/or insert one or more padded dunnage support via the openings in opposed tracks. 
     The ease of operation and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the brief description thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the invention. 
         FIG. 1  is a perspective view of one embodiment of a reusable and returnable container; 
         FIG. 2A  is an enlarged perspective view of a portion of the container of  FIG. 1  without the dunnage and padded dunnage supports; 
         FIG. 2B  is a cross-sectional view of a portion of the container of  FIG. 1  without the dunnage and padded dunnage supports; 
         FIG. 2C  is a cross-sectional view of a portion of the container of  FIG. 1  without the dunnage and padded dunnage supports; 
         FIG. 3A  is an enlarged view of the encircled area  3 A of  FIG. 1 ; 
         FIG. 3B  is a cross-sectional view taken along the line  3 B- 3 B of  FIG. 3A ; 
         FIG. 4A  is a cross-sectional view of the container of  FIG. 1  loaded with products; 
         FIG. 4B  is a cross-sectional view of a portion of the container of  FIG. 1 , showing the door assembly in a lowered position; 
         FIG. 4C  is a cross-sectional view of a portion of the container of  FIG. 1 , showing a front product being removed; 
         FIG. 4D  is a cross-sectional view of a portion of the container of  FIG. 1 , showing a rear product being removed; 
         FIG. 4E  is a cross-sectional view of a portion of the container of  FIG. 1 , showing all products removed; 
         FIG. 5A  is a cross-sectional view of a portion of the container of  FIG. 1 , showing a product being inserted into a rear pouch; 
         FIG. 5B  is a cross-sectional view of a portion of the container of  FIG. 1 , showing a second product being inserted into a pouch; 
         FIG. 5C  is a cross-sectional view of a portion of the container of  FIG. 1 , showing a product being inserted into a front pouch; 
         FIG. 5D  is a cross-sectional view of a portion of the container of  FIG. 1 , showing the door assembly being raised; 
         FIG. 5E  is a cross-sectional view of a portion of the container of  FIG. 1 , showing the container fully loaded and ready for shipment; 
         FIG. 6  is a perspective view of one embodiment of a reusable and returnable container; 
         FIG. 7  is a perspective view of a portion of the container of  FIG. 6  without the door assembly and without the dunnage and padded dunnage supports; 
         FIG. 8A  is an enlarged perspective view of a portion of the container of  FIG. 6  without the dunnage and padded dunnage supports; 
         FIG. 8B  is a cross-sectional view of a portion of the container of  FIG. 6  without the dunnage and padded dunnage supports; 
         FIG. 9  is a cross-sectional view of a portion of the container of  FIG. 6  without the dunnage and padded dunnage supports; and 
         FIG. 10  is a cross-sectional view of the container of  FIG. 6  loaded with products. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1 , there is illustrated a reusable and returnable container  10  according to one embodiment. The reusable and returnable container  10 , as shown, comprises a body  12  having a base  14 , opposed sides  16  and a rear  18 , all extending upwardly from the base  14 . The sides  16  and rear  18  may be hingedly secured to the base  14 . The base  14  may have a plurality of passages  15  therethrough adapted to receive the prongs of a forklift for purposes of lifting and moving the container  10 . Although one configuration of body in the form of a pallet box is illustrated, the present invention may be used with other types or configurations of container bodies. 
     As best shown in  FIG. 2B , container  10  further comprises two guide members  20  (only one being shown in  FIG. 2 ). One guide member  20  is fixedly secured to each of the container sides  16  with fasteners  22 . Each of the guide members  20  has two slots therethrough, an upper slot  24  and a lower slot  26 . As best shown in  FIG. 2B , upper slot  24  has a “candy cane” shape comprising a straight portion  28  and a curved upper portion  30 . These upper and lower slots  24 ,  26  are used to secure a movable door assembly  32  in a fixed position and guide the door assembly  32  during its movement from an upper or raised position shown in  FIGS. 1 and 4A  and a lower or dropped position shown in  FIG. 4B . As best shown in  FIG. 1 , the upper segment  34  of door assembly  32  comprises an upper piece  5  which may function as a handle, a lower piece  6  and two side pieces  7  joined together to create a rectangular frame  8  inside which is a door panel  9 . In one embodiment, the door panel  9  is made of plastic and the frame  8  made of metal. However, any desired materials may be used. 
     As shown and described in pending U.S. patent application Ser. No. 13/896,675 and pending U.S. patent application Ser. No. 13/975,682, each application of which is fully incorporated herein, the door assembly  32  may comprise one or more movable segments. Although the drawings show a door assembly  32  having a movable upper segment  34  and a movable lower segment  35  which are not connected together, any of the door assemblies disclosed in pending U.S. patent application Ser. No. 13/896,675 or pending U.S. patent application Ser. No. 13/975,682 may be incorporated into a container in accordance with the present invention. 
     As shown in the drawings, the movable upper segment  34  of door assembly  32  has a pair of upper pins  36 , one on each side (only one being shown) extending outwardly from the movable upper segment  34  of door assembly  32  and adapted to ride or move inside the upper slots  24 . Similarly, the movable upper segment  34  of door assembly  32  has a pair of lower pins  38  extending outwardly from the movable upper segment  34  of door assembly  32 , one on each side (only one being shown). These lower pins  38  are adapted to ride or move inside the lower slots  26 .  FIG. 4A  shows the movable upper segment  34  of door assembly  32  locked in a raised position with the upper pins  36  located at the outer ends of the curved portions  30  of the upper slots  24 . As the movable upper segment  34  of door assembly  32  is lowered, it moves outside a stationary shield  40 . As best shown in  FIGS. 1 and 4A , the stationary shield  40  has a flange  42  and a main portion  44 . The flange  42  of the stationary shield  40  is secured with fasteners  46  to the container&#39;s base  14 . 
     The lower movable segment  35  of door assembly  32  is not fastened or secured to any particular piece and is free floating between the stationary shield  40  and the movable upper segment  34  of door assembly  32 . As best shown in  FIG. 4A , movable lower segment  35  of door assembly  32  is generally C-shaped in cross-section, having an outwardly directed upper flange  48  located at the upper end of the movable lower segment  35  and a lower flange  50  located at the lower end of the lower segment  35 . The movable lower segment  35  of door assembly  32  moves inside a stationary vertically oriented main portion  44  of the stationary shield  40 . As the movable upper segment  34  of door assembly  32  is lowered, the movable lower segment  35  of door assembly  32  moves inside the main portion  44  of the stationary shield  40 . As the movable upper segment  34  of door assembly  32  is raised, the flange  52  of the movable upper segment  34  of door assembly  32  contacts the upper flange  48  located at the upper end of the lower segment  35  and raises the floating lower segment  35  of door assembly  32 . 
     As shown in  FIG. 4B , when the door assembly  32  is in its lowered position, an opening having a height H 1  is created above the door assembly  32 . The height H 1  of the opening is greater than half the height of the container, making it desirable from an ergonomic standpoint for the loader/unloader. 
     As best shown in  FIGS. 1 and 4A , multiple protective bumpers  54 , may be secured to upper segment  34  of door assembly  32 . The bumpers  54  may be made of foam or any other suitable material. When the door assembly  32  is in its lowered position shown in  FIG. 4B , the bumpers  54  may function to prevent products  100  from hitting the door assembly  32  during the loading or unloading process. Although two bumpers  54  are illustrated secured to the upper segment  34  of door assembly  32 , a continuous bumper or a different number of bumpers may be utilized of any desired configuration or size. If desired, bumpers  54  may be omitted. 
     As shown in  FIGS. 2B and 2C , a protector  56  may be secured to each of the sides  16  (only one being shown) with fasteners  58 . Each protector  56  prevents product  100  from contacting the container sides  16  and from being scratched or damaged. The protectors  56  may be made of foam or any other suitable cushioning material. If desired, protectors  56  may be omitted. 
     As shown in  FIG. 2C , a stationary generally L-shaped track  60  is supported by each side  16  of the container  10 . Each generally L-shaped track comprises a generally horizontally oriented track portion  62  and a generally vertically oriented track portion  64 , each portion  62 ,  64  being fixedly secured to a side  16  of the container  10 . 
     As shown in  FIG. 2A , the generally horizontally oriented track portion  62  has a pair of tabs  66  extending downwardly from the track portion  62  (only one being shown). Each tab  66  extends through a slot  68  in a wall protector  72  and has an opening  70  extending through the tab  66 . When the tabs  66  are passed through the slots  68 , the openings  70  in tabs  66  align with openings  74  in the wall protector  72 . Each fastener  76  extends through an opening  74  in the wall protector  72 , through an opening  70  in one of the tabs  66  and into the side  16  of container  10  to secure the wall protector  72  and generally horizontally oriented track portion  62  to the side  16  of the container. In addition, additional fasteners  78  secure a lower portion of the wall protector  72  to the container side  16 . 
     As best shown in  FIG. 2B , to secure the generally vertically oriented track portion  64  of generally L-shaped track  60  to the container side  16 , fasteners  22  extend through openings  80  in the track portion  64 , through a portion of a guide member  20  and into a container side  16 . 
     As best shown in  FIG. 3A , the generally horizontally oriented track portion  62  of generally L-shaped track  60  has an upper wall  82 , a lower wall  84  joined to the upper wall  82  by a side wall  86 , and a lip  88  extending downwardly from the upper wall  82  and another lip  90  extending upwardly from the lower wall  84  defining an interior  102  of the generally horizontally oriented track portion  62  of generally L-shaped track  60 . 
     As best shown in  FIG. 2C , generally vertically oriented track portion  64  and generally horizontally oriented track portion  62 , each being fixedly secured to one of the sides  16 , do not move after the container  10  is assembled and do not move relative to the sides  16  of the container  10  during the loading or unloading of parts or product. On each side of the container, the top of the generally vertically oriented track portion  64  may connect or communicate with the front end of the generally horizontally oriented track portion  62  at corner  65 . The generally vertically oriented track portion  64  may be the same construction and/or material as the horizontally oriented track portion  62 , or they may be slightly different. The interior  92  of the generally horizontally oriented track portion  62  connects with the interior of the generally vertically oriented track portion  64  so that one of the padded dunnage supports  94  may move along a continuous path in both a horizontal and vertical direction. The generally horizontally oriented track portion  62  and generally vertically oriented track portion  64  may be separate pieces welded or joined together, or may be a unitary generally “L-shaped” piece of track fixedly secured to each of the container sides  16 . In either event, a corner piece (not shown) may be welded or otherwise secured to each corner  65  to prevent the end members or portions of the padded dunnage supports  94  from coming out of the tracks at the corner. As best shown in  FIG. 4C , the generally horizontal portion  62  of the generally L-shaped track  60  has an inhibitor, bump or curved portion  59  located at the intersection of the generally horizontal track portion  62  and generally vertically oriented track portion  64  to maintain the padded dunnage supports  94  in positions extending between the generally horizontal track portions  62  of the generally L-shaped tracks  60 , as shown in  FIG. 2 . 
     Referring to  FIG. 1 , container  10  further comprises a plurality of padded dunnage supports  94  extending between the tracks  60  on opposed sides of the container. When the container  10  is fully loaded with product, as shown in  FIG. 4A , each padded dunnage support  94  extends between the generally horizontally oriented track portions  62  of generally L-shaped tracks  60  at the same level on opposed sides of the container. At the corner of each generally L-shaped track  60  is an inhibitor or curved portion  59  which aids in maintaining the padded dunnage supports  94  in positions extending between the generally horizontally oriented track portions  62  of generally L-shaped tracks  60 . 
     As shown in  FIG. 3A , padded dunnage support  94 , along with each of the other padded dunnage supports, includes a pair of end members  98  and a tubular support or middle member  102  having a hollow interior  104  extending therebetween. The end members  98  are preferably made of injection molded plastic, such as nylon, but may be made of any other material. The tubular support  104  is preferably made of metal, but may be made of other suitable material, such as plastic. 
     As shown in  FIG. 3A , each end member  98  preferably has a first portion  106  having an X-shaped cross-sectional configuration and a second portion  108  having a circular cross-sectional configuration. Although one configuration of end member  98  is illustrated, any type or configuration of end member may be used with the present invention. In this embodiment, each end member  98  has a pair of heads  110 ,  112  at the end of the end member  98 . As best shown in  FIG. 3B , head  110  is furthest from the first portion  106  of the end member  98 , and head  112  is spaced inwardly from head  110 . The heads  110 ,  112  are spaced from one another to define a groove  114  therebetween which receives and retains the lips  88 ,  90  of either the generally horizontally oriented track portion  62  of generally L-shaped track  60  or the generally vertically oriented track portion  64  of generally L-shaped track  60 . As shown in  FIG. 3A , head  110  is located inside the interior  92  of the generally horizontally oriented track portion  62  of generally L-shaped track  60  or the interior of generally vertically oriented track portion  64  of generally L-shaped track  60 . Head  112  is located outside the interior  92  of the generally horizontally oriented track portion  62  of generally L-shaped track  60  or the interior of generally vertically oriented track portion  64  of generally L-shaped track  60 . Head  110  keeps the end member  98  engaged with the track, while head  112  keeps the dunnage material out of the interior  92  of the track, thereby ensuring that the end members  98  may move smoothly along either the generally horizontally oriented track portion  62  of generally L-shaped track  60  or the interior of generally vertically oriented track portion  64  of generally L-shaped track  60 . Although one configuration of padded dunnage support is illustrated, the present invention may be used with any type or configuration of dunnage support for supporting dunnage so the dunnage may slide or move inside the container. 
     As shown in  FIG. 3B , each end of tubular support  102  fits over at least one portion  108  of an end member  98 . An end surface  116  of tubular support  102  abuts head  112  of end member  98 . Each end member  98  of each padded dunnage support  94  is adapted to engage and move along one of the tracks. The end members  98  preferably slide along the length or width of the tracks; however, different end members may rotate rather than slide along the tracks. Although one configuration of track and end member is shown and described, other types of end members and tracks may be used if desired. For example, the one-piece dunnage supports and tracks disclosed in U.S. patent application Ser. No. 13/225,835, which is fully incorporated by reference herein, may be used. 
     As best shown in  FIG. 3B , padded dunnage support  94 , along with each of the other padded dunnage supports, includes a pair of end members  98  (only one being shown in  FIG. 3B ). Each end member  98  has a groove  120  formed in a portion  108  therein. Padded dunnage support  94 , along with each of the other padded dunnage supports, further includes a tubular support  102  having a hollow interior  104  extending therebetween. As shown in  FIG. 3A , each end of tubular support  98  fits over at least one portion  106  of an end member  98 . An end surface  116  of tubular support  102  abuts head  112  of end member  98 . As shown in  FIG. 3B , tubular support  102  has two detents  118  therethrough (one at each end) in which the material of the tubular support  102  is pressed downwardly into the groove  120 . This attachment between each of the two end members  98  and the tubular support  102  enables some movement therebetween. Such interaction between the end members  98  and tubular support  102  allows for a tolerance of approximately one-quarter inch on each side. The detents  118  prevent separation of the tubular support  102  from the end members  98  while allowing some movement therebetween as the detents  118  move within the grooves  120  formed in the end members  98 . 
     As best illustrated in  FIG. 3A , a cushioning cylinder, sleeve or “noodle”  150  at least partially surrounds the tubular support or middle member  102  of the padded dunnage support  94 . The cushioning cylinder  150  is preferably made of polyethylene foam, but may be made of any desirable cushioning or padding material. Each cushioning cylinder  150  may have a central opening  152  extending along its longitudinal axis through which one of the tubular supports  102  passes. In one embodiment, each cushioning cylinder  150  has a diameter of 3.5 to 4.0 inches. However, any sized cushioning cylinder may be used for any particular design. One purpose of the cushioning cylinders  150  is to protect the parts inside the dunnage from contacting each other and damaging each other during shipment as well as during the loading and/or unloading processes. The padded dunnage supports  94  prevent part-to-part contact during shipment by increasing the spacing between adjacent padded dunnage supports  94 , and thus increasing the spacing between the parts  100 . With parts having a unique configuration, such spacing may be necessary to avoid part-to-part contact and resulting damage to the parts during shipment. One such part may have an upper portion wider than its lower portion, as shown generally in the drawings. Although one configuration of part  100  is illustrated, any of the containers shown or described herein may be used to ship or store other parts having other configurations. The generally horizontally oriented track portions  62  of generally L-shaped tracks  60  are located approximately half way up the sides  16  of container  10  to accommodate parts  100  having an upper portion larger than the part&#39;s lower portion. Such a configuration enables the maximum number of parts  100  to fit inside the container  10  without damaging each other during shipment. 
       FIG. 3A  illustrates a padded dunnage support  94  used to support one side of one of the pouches. However,  FIG. 3A  illustrates another innovative feature or aspect of the invention. The generally horizontally oriented track portion  62  of each generally L-shaped track  60  may have an opening or cut-out  122  formed therein. Holes  124  may be formed in the upper wall  82  of the generally horizontally oriented track portion  62  of generally L-shaped track  60 , which are sized and threaded to receive fasteners  126 . Although fasteners  126  are illustrated to be screws, they may be any other desirable fastener. A cap  128  may be removably secured to the generally horizontally oriented track portion  62  of generally L-shaped track  60  to cover the opening or cut-out  122  formed in the generally horizontally oriented track portion  62  of generally L-shaped track  60 . As best seen in  FIG. 3A , cap  128  has a generally inverted U-shaped cross-sectional configuration, including a top portion  130  and side portions  132  extending downwardly from the top portion  130 . Holes  134  are formed through the top portion  130  of the cap  128  and sized to receive fasteners  126 , as shown in  FIG. 3A . The fasteners  126  are adapted to pass through the holes  134  in the cap  128  and into the holes  124  in the upper wall  82  of the generally horizontally oriented track portion  62  of generally L-shaped track  60 . Caps of alternative shapes or sizes may be used if desired. 
     When one of the end members  98  or any part of any of the padded dunnage supports is damaged or needs to be replaced for any reason, one may remove cap  128  after loosening fasteners  126 , thereby exposing the opening or cut-out  122  of the generally horizontally oriented track portion  62  of generally L-shaped track  60 . The damaged padded dunnage support may then be removed or inserted as necessary to repair or replace the damaged part or parts. 
     As best shown in  FIG. 4A , dunnage  136 , in the form of a plurality of pouches  138 , is suspended by and supported by a plurality of padded dunnage supports  94 . Each pouch  138  has a front wall  140 , a rear wall  142  and a bottom  144 . In some applications, each pouch  138  may have two side walls extending between the front and rear walls  140 ,  142 . As shown in  FIG. 4A , the top of the front wall  140  is attached to one of the dunnage supports  94 , and the rear wall  142  is attached to an adjacent dunnage support. Although the dunnage  136 , as shown, comprises pouches, the dunnage may assume other shapes or configurations. A pouch  138  is supported by two adjacent dunnage supports. As shown in  FIG. 3A , the fabric of the pouch  138  is sewn or otherwise secured together along a seam  146  to make a pocket  148  in which is located a cushioning cylinder  150  surrounding, at least partially, a tubular support  102  of the padded dunnage support. As shown in  FIG. 1 , a handle  162  may be sewn or otherwise secured to an upper portion of one or more pouches  138  above one or more of the padded dunnage supports  94 . 
     Padded dunnage supports  94  supporting pouches  138  are adapted to move from back to front inside the interior of the container  10 , the end members  98  of the padded dunnage supports  94  moving along the stationary tracks  60  in generally horizontal and vertical directions. 
     Multiple pouches  138  are shown being formed or created from one piece of material draped or laying over and secured to the dunnage supports  94 . Alternatively, each pouch  138  may be made from its own piece of material, in which case, the pouches  138  would not be interconnected other than via the straps or space limiters (not shown). 
       FIGS. 4A-4E  illustrate a method of unloading products  100  from the pouches  138  of the container  10 . The method comprises the first step of lowering upper door segment  34  and lower door segment  35  of door assembly  32  from a raised and locked position shown in  FIG. 4A  to a lowered or dropped position illustrated in  FIG. 4B . As shown in  FIG. 4A , when the door assembly  32  is in its raised and locked position, the front padded dunnage support  94  is prevented from moving through the inhibitor  59  and into the generally vertically oriented track portion  64  of generally L-shaped track  60  by the cushioning cylinder  150  of the front padded dunnage support  94  contacting the upper door segment  34  of door assembly  32 . However, when the door assembly  32  is in a lowered position, the upper door segment  34  of door assembly  32  does not prevent the front padded dunnage support  94  from moving through the inhibitor  59  and into the generally vertically oriented track portion  64  of generally L-shaped track  60 . As shown in  FIG. 4B , when the door assembly  32  is in a lowered position, an opening having a height H 1  is created above the door assembly  32  to assist an operator in loading and unloading products  100  into and out of pouches. In order to move the door assembly  32  out of its raised and locked position shown in  FIG. 4A , an operator must grasp the upper piece or handle  5  of the upper segment  34  of door assembly  32  and lift the door assembly  32  upwardly so the upper pins  36  move upwardly and outwardly, following the path of the curved upper portion  30  of the upper slots  24  of the guide members  20 . Once the upper pins  36  of door assembly  32  reach the linear portion  28  of the upper slots  24  of the guide members  20 , the door assembly  32  moves further downwardly due in part to gravity, the lower pins  38  traveling along the lower slots  26  of the guide members  20  until the door assembly  32  reaches its open or lowered position shown in  FIG. 4B . 
     As shown in  FIG. 4C , with the door assembly  32  in its lowered position, the next step comprises moving the front padded dunnage support  94  forwardly, the end members  98  sliding in the stationary generally horizontally oriented track portions  62 , from its position shown in  FIG. 4A  over the inhibitors or curved portions or bumps  59  and into the generally vertically oriented track portions  64  to a position shown in  FIG. 4C . At this point, the product  100  in the forwardmost or front pouch  138  is still in the front pouch  138 , as shown in  FIG. 4C . As shown in  FIG. 3C , the product  100  in the front pouch  138  is then removed by the operator in the direction shown by arrow  154  over the lowered door assembly  32 . Thus, the front product  100  being removed passes between the partially lowered or dropped first padded dunnage support  94  and the second padded dunnage support  94 , which is still extending between the generally horizontally oriented track portions  62 . As shown in  FIG. 4C , the lowered position of the door assembly  32  makes it easier from an ergonomic standpoint for the operator to remove the product  100  because the product  100  need not be raised over the full height of the container  10  to be removed from inside the container. As shown in  FIG. 4C , when the front padded dunnage support  94  is located extending between the generally vertically oriented track portions  64  of the generally L-shaped tracks  60 , and next padded dunnage  94  is located extending between the generally horizontally oriented track portions  62  of the generally L-shaped tracks  60 , an operator may easily remove a product  100  inside the front pouch  138  because one padded dunnage support  94  is below the adjacent padded dunnage support  94 . This orientation of the padded dunnage supports due to the configuration of the L-shaped tracks  60  helps an operator from an ergonomic standpoint, reducing the stress and strain on the body of the operator when unloading product from the dunnage. Thus, the unique configuration of the upper generally L-shaped tracks  60  inside the container  10  may reduce the container owner&#39;s costs because workers or operators may have fewer injuries/days off due to injury. 
     As shown in  FIG. 4D , this unloading process is continued by an operator one product at a time until all of the last product  100  is removed from the last pouch  138  in the direction of arrow  156 . During the process of unloading the last product  100 , each of the padded dunnage supports  94 , except the last two, extends between the generally vertically oriented track portions  64 . Each time a product  100  is removed from a pouch  138 , the padded dunnage support  94  and associated dunnage are moved along the generally L-shaped tracks  60  in a generally counter-clockwise direction, as shown in  FIG. 4A-4D . During this unloading process, the end members  98  at the ends of the padded dunnage supports  94  move along the generally L-shaped tracks  60 . 
     As shown in  FIG. 4E , the empty container  10  still having the dunnage therein is then shipped back to its desired location for loading additional product. During the unloading or loading process, the tracks  60  remain stationary fixedly secured to the container sides  16 ; and it is the padded dunnage supports  94  and dunnage hanging from the padded dunnage supports  94  which move inside the container with the assistance of an operator. 
       FIG. 4E  illustrates the empty container  10  still having the dunnage therein, which may then be shipped back to its original location or any desired location for loading the empty dunnage with product. 
       FIGS. 5A-5F  illustrate a method of loading product  100  into the pouches  138  of emptied container  10 . As shown in  FIG. 5A , the first step of the loading process comprises loading a product  100  into rear pouch  138  (furthest away from the front of the container) in the direction of arrow  158 . 
     As shown in  FIG. 5B , the next step comprises moving padded dunnage supports  94  supporting the loaded pouch  138  towards the rear of the container, the end members  98  of padded dunnage supports  94  moving along the generally horizontally oriented track portions  62  of generally L-shaped tracks  60 , the loaded rear pouch  138  containing a product  100 . The process of loading one pouch at a time continues until each pouch  138  is full.  FIG. 5C  illustrates an operator (not shown) loading a product  100  into front pouch  138  (closest to the front of the container) in the direction of arrow  160 . 
     As shown in  FIG. 5D , the next step comprises raising the front padded dunnage support  94  inside the generally vertically oriented track portions  64  of generally L-shaped tracks  60  upwardly around the curved portions or inhibitors  59  and into the generally horizontally oriented track portions  62  of generally L-shaped tracks  60 . 
     As shown in  FIG. 5D , the next step comprises raising the door assembly  32  in the direction of arrow  162  to its raised and locked position. Once all of the pouches  138  have been loaded with product  100 , and the door assembly  32  fixed in its raised and locked position shown in  FIG. 5E , the full container may be shipped to its desired destination. 
       FIG. 6  illustrates a reusable and returnable container  10   a  according to another embodiment. The reusable and returnable container  10   a , as shown, comprises an outer metal frame  164  having a base  166 , two rear corner posts  168  and two front corner posts  170 , all four corner posts  168 ,  170  extending upwardly from the base  166 . 
     As best shown in  FIG. 7 , the base  166  is generally rectangular in shape and comprises a front member  172 , a rear member  174  and two side members  176 . The members of the base  166  may be secured together or secured to the corner posts  168 ,  170  via any conventional means, including welding. Stubs  178  extend upwardly from the base  166  and are secured thereto by welding, for example. 
     As best shown in  FIG. 7 , a generally rectangular sub-base  180  is spaced above the base  166  by the stubs  178  and secured to the stubs  178  by welding, for example. The sub-base  180  comprises a front member  182 , a rear member  184  and two side members  186 . The members of the sub-base  180  may be secured together or secured to the corner posts  168 ,  170  via any conventional means, including welding. Although two stubs  178  are shown extending upwardly from each of the base members  172 ,  174  and  176  to corresponding sub-base members  182 ,  184  and  186 , any number of stubs  178  may be used to space the sub-base  180  above the base  166 . 
     As best shown in  FIG. 7 , the sub-base  180  of the container  10   a  further comprises a plurality of intersecting interior members  188  extending between opposed perimeter sub-base members  182 ,  184  and  186  and secured thereto, interior members  188  comprising part of the sub-base  180  of the metal frame  164 . Although five interior members  188  are shown in the sub-base  180  of the container  10   a , any number of interior members may be used. 
     As best shown in  FIG. 10 , each of the corner posts  168  and  170  may be generally rectangular in cross-section, have a hollow interior, and a knob  190  at the top thereof for stacking purposes so that multiple containers  10   a  may be stacked upon one another. The knobs  190  of a first container fit inside the hollow interiors of the corner posts of another or second container located above the first container for stacking purposes. 
     As best shown in  FIG. 7 , metal frame  164  further comprises an upper rear member  192  and a rear panel  194  extending between the two rear corner posts  168  and being secured thereto. The rear panel  194  is below the upper rear member  192 . The metal frame  164  further comprises, on each side of the container, an upper side member  196  and a side panel  198  extending between one of the rear corner posts  168  and one of the front corner posts  170  and secured thereto. On each side, upper side member  196  is located above side panel  198 . 
     Although one type of metal frame is illustrated, the present invention may be used with other types or configurations of outer metal frames, such as the outer metal rack disclosed in U.S. patent application Ser. No. 14/054,271, which is fully incorporated by reference herein. In many racks intended to be within the scope of the present invention, each side wall is a solid wall. 
     As best illustrated in  FIGS. 8B and 9 , a floor  200  rests on top of sub-base  180  of the metal frame  164  of container  10   a . The floor  200  may be made of plastic, wood, metal or any other desired material. Although the floor  200  is illustrated as being one piece or panel, more than one piece or panel may comprise the floor  200  resting on top of sub-base  180  of the metal frame  164  of container  10   a.    
     All the remaining components of container  10   a  are identical to those of container  10  shown in  FIGS. 1-5C . For the sake of simplicity, like parts have like numbers. 
     Although one specific shape of product  100  is illustrated in the drawings, this document is not intended to limit in any way the size, shape or configuration of product shipped or stored in any of the embodiments described or shown herein. 
     While various embodiments of the present invention have been illustrated and described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspect is, therefore, not limited to the specific details, representative system, apparatus, and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant&#39;s general inventive concept.