Patent Abstract:
A container for holding product therein during shipment and being returned for reuse has a base and opposite sides. The container has multiple levels of dunnage components, the dunnage components of at least one level being movable between open and closed positions to enable an operator to load and unload products more easily. The dunnage components of at least one level may have openings through which pass guides supported at least partially by the container.

Full Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to containers for use in shipping and, more particularly, to containers with movable dunnage for supporting product during shipment and/or storage. 
       BACKGROUND OF THE INVENTION 
       [0002]    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. 
         [0003]    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. 
         [0004]    In many containers, a line worker or employee must insert or remove parts from a lower part of the container. Sometimes the size and/or weight and/or configuration of the parts or work pieces may make inserting or removing such parts from a lower level of the container difficult due, in part, to the configuration or location of the dunnage inside the container. Such difficulty may cause stress or strain on the line worker and, more particularly, on the back of the worker when inserting or removing parts from the lower part of such a container. Such ergonomically unfriendly movements may cause physical trauma, pain and other injuries that may lead to lost production time. 
         [0005]    Therefore, there is a need for a container with movable dunnage inside the container so an operator may more easily load or unload parts from inside the container. Such movable dunnage may alleviate stress and/or strain on the operator&#39;s body during loading and/or unloading processes. 
         [0006]    Containers having movable dunnage in the form of pouches are known. Such containers may be adapted to store and ship parts residing inside the pouches. Some parts or products are more easily, cost effectively and/or safely shipped/stored in dunnage other than pouches. 
         [0007]    Accordingly, there is a need for a container having movable dunnage in a form other than pouches. 
         [0008]    There is further a need for a container having multiple levels of dunnage other than pouches in order to ship additional parts or products. 
       SUMMARY OF THE INVENTION 
       [0009]    The present invention provides a container for holding product therein during shipment and/or storage that has a body and upper and lower levels of dunnage components supported, at least in part, by the body. For purposes of this document, the term dunnage component refers to both a single dunnage member and multiple pieces or members joined together into a dunnage assembly. In some embodiments, at least one movable dunnage component may move above at least one stationary dunnage component for ease of loading/unloading products into the dunnage for shipment or storage. In some embodiments, two movable upper dunnage components may be moved away from each other or separated in order to aid the loading or unloading of parts into or out of the lower level of dunnage. Separating the upper dunnage components increases the size of an opening through which a part must pass to be loaded into the lower level of dunnage or unloaded from the lower level of dunnage. In other embodiments, only one of the two upper dunnage components may be movable. 
         [0010]    According to one aspect of the present invention, the container has a base and at least two opposed walls or side structures. The container further comprises upper and lower levels of dunnage for holding products during storage and shipment. The lower level of dunnage is often stationary, but may be movable in certain applications. The upper level of dunnage components may be at least partially movable to facilitate insertion and removal of products from an interior of the container. Supports are operatively coupled to opposed side structures of the container and guides supported by the supports. The upper level of dunnage comprises multiple dunnage components. The guides direct at least one of the upper dunnage components to a desired position away from another dunnage component to facilitate insertion and removal of products from the lower level of dunnage. 
         [0011]    At least one of the dunnage components may include a dunnage member made at least partially of foam. Any other material, such as plastic or wood, may be used for the dunnage components of either level. 
         [0012]    The container guides may be rails, beams, rods or tubes made of metal, such as aluminum, or any other suitable material. The guides may extend the length or width of the interior of the container. Alternatively, each of the guides may be less than the length or width of the container&#39;s interior. 
         [0013]    According to another aspect of the invention, the container comprises a base and at least two opposed side structures. The container further comprises supports operatively coupled to opposed side structures of the container. The container has multiple levels of dunnage for holding products during storage and shipment. At least one level of dunnage may be stationary. At least one level of dunnage may be at least partially movable to facilitate insertion and removal of products into and out of a lower level of dunnage. Guides may be supported by the supports, the guides directing at least one dunnage component of the upper level of dunnage to a desired position to facilitate removal or insertion of products into and out of the lower level of dunnage. The upper level of dunnage may comprise two dunnage components, each of the upper dunnage components having at least one opening which one of the guides passes, such that the upper dunnage component may be guided to a desired position. 
         [0014]    According to another aspect of the invention, a method of unloading products from inside a container is disclosed. The method comprises removing products extending between movable dunnage components of an upper level of dunnage. At least one of the dunnage components of the upper level of dunnage is movable away from another dunnage component of the upper level of dunnage. The next step comprises moving at least one of the dunnage components of the upper level of dunnage from a first position to a second position, the dunnage components of the upper level of dunnage being further away from each other in the second position than in the first position. The next step comprises removing products of a lower level of dunnage while the dunnage components of the upper level of dunnage are in their second position. 
         [0015]    According to another aspect of the invention, a method of loading products into a container is disclosed. The method comprises inserting products into a lower level of dunnage while dunnage components of an upper level of dunnage are spaced away from each other in an open position. At least one of the dunnage components of the upper level of dunnage is movable away from another of the dunnage components of the upper level of dunnage. The next step comprises moving the dunnage components of the upper level of dunnage towards each other into a closed position. The last step comprises inserting products into notches into the upper level of dunnage. 
         [0016]    According to another aspect of the invention, a method of loading products into a container is disclosed. The method comprises inserting products into a lower level of dunnage while dunnage components of an upper level of dunnage are spaced away from each other in an open position. The next step comprises moving the dunnage components of the upper level of dunnage towards each other into a closed position. The last step comprises inserting products into the dunnage components of the upper level of dunnage. 
         [0017]    According to another aspect of the invention, a method of unloading products from inside a container is disclosed. The method comprises removing products from an upper level of dunnage. The next step comprises moving the dunnage components of the upper level of dunnage from a first position to a second position, the dunnage components of the upper level of dunnage being further away from each other in the second position than in the first position. The last step comprises removing products from a lower level of dunnage while the dunnage components of the upper level of dunnage are in their second position. 
         [0018]    The container may have at least one door. The movable dunnage of the upper level allows product to be more efficiently and safely removed from the container or inserted therein without unnecessary stress or strain on the operator. Although the containers shown and described herein contain two levels or layers of dunnage, the container may have three or more layers or levels of dunnage. 
         [0019]    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 
         [0020]    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. 
           [0021]      FIG. 1  is a perspective view of one embodiment of a reusable and returnable container; 
           [0022]      FIG. 2  is a perspective view of the container of  FIG. 1  showing the dunnage inside the container; 
           [0023]      FIG. 3  is an enlarged perspective view of a portion of the container shown in  FIGS. 1 and 2 ; 
           [0024]      FIG. 3A  is an enlarged perspective view of a portion of another embodiment of container having upper dunnage components comprising unitary pieces; 
           [0025]      FIG. 3B  is an enlarged perspective view of a portion of another embodiment of container having different upper dunnage components; 
           [0026]      FIG. 3C  is an enlarged perspective view of a portion of another embodiment of container having different upper dunnage components; 
           [0027]      FIG. 3D  is an enlarged perspective view of a portion of another embodiment of container having different upper dunnage components and different guides; 
           [0028]      FIG. 4  is a partial cross-sectional view of a portion of the container shown in  FIG. 1 ; 
           [0029]      FIG. 5  is a partial cross-sectional view, like  FIG. 4 , showing a different upper dunnage component; 
           [0030]      FIG. 6A  is a cross-sectional view of the container shown in  FIG. 1 , the dunnage components of the upper level being shown in a closed position and products being shown in dashed lines; 
           [0031]      FIG. 6B  is a cross-sectional view of the container shown in  FIG. 6A , the dunnage components of the upper level being shown in an open position and products of the lower level being shown in dashed lines; 
           [0032]      FIG. 6C  is a cross-sectional view of the container shown in  FIG. 6B , the dunnage components of the upper level being shown in an open position and products of the lower level being removed from inside the container; 
           [0033]      FIG. 6D  is a cross-sectional view of the container shown in  FIG. 1 , products being loaded into the dunnage components of the lower level; 
           [0034]      FIG. 6E  is a cross-sectional view of the container shown in  FIG. 6D , the dunnage components of the upper level shown being moved to a closed position after the lower level of dunnage is fully loaded with products; 
           [0035]      FIG. 6F  is a cross-sectional view of the container shown in  FIG. 6D , the dunnage components of the upper level being shown in a closed position and products being loaded into the dunnage of the upper level; 
           [0036]      FIG. 7  is a perspective view of another embodiment of a reusable and returnable container; 
           [0037]      FIG. 8  is a perspective view of the container of  FIG. 7  showing the dunnage inside the container; 
           [0038]      FIG. 9  is a partial cross-sectional view of a portion of the container shown in  FIGS. 7 and 8 ; 
           [0039]      FIG. 10  is a perspective view of another embodiment of a reusable and returnable container; 
           [0040]      FIG. 11  is a perspective view of the container of  FIG. 10  showing a door or portion of the container being removed; 
           [0041]      FIG. 12  is an enlarged perspective view of a portion of the container shown in  FIG. 10 ; 
           [0042]      FIG. 13  is a partial cross-sectional view of a portion of the container shown in  FIGS. 10 and 12 ; 
           [0043]      FIG. 14  is a perspective view of another embodiment of a reusable and returnable container; 
           [0044]      FIG. 15  is a perspective view of the container of  FIG. 14  showing the dunnage inside the container; 
           [0045]      FIG. 16  is an enlarged perspective view of a portion of the container shown in  FIGS. 14 and 15 ; 
           [0046]      FIG. 17  is a partial cross-sectional view of a portion of the container shown in  FIG. 14 ; 
           [0047]      FIG. 18  is a perspective view of another embodiment of a reusable and returnable container; and 
           [0048]      FIG. 19  is a perspective view of the container of  FIG. 18  turned upside down. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0049]    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 side walls  16 , a front wall  18  and a rear wall  20 , all of the walls or side structures extending upwardly from the base  14 . Two or more of the walls or sides  16 ,  18  and  20  may or may not be hingedly secured to the base  14 . 
         [0050]    The base  14  has an upper surface which functions as a floor  22  of the interior  24  of the container. Each of the side walls  16  has an inner surface  26 . The rear wall  20  has an interior surface  28  and the front wall  18  has an interior surface  30 . The floor  22 , interior surfaces  26  of side walls  16  and interior surfaces  30 ,  28  of the front and rear walls  18 ,  20 , respectively, define the interior  24  of the container  10 . The linear distance between the interior surfaces  26  of the side walls  16  defines a width “W” of the interior of the container. The linear distance between the interior surfaces  30 ,  28  of the front and rear walls  18 ,  20 , respectively, defines a length “L” of the interior  24  of the container  10 . See  FIG. 1 . 
         [0051]    The present invention is not intended to limit the size or configuration of the container base and walls. Although one type of container is illustrated, the present invention may be used with other types or configurations of container. 
         [0052]    Container  10  further comprises a pair of spaced stationary supports  32  operatively coupled to the rear wall  20  of the container  10  (only one being shown in  FIG. 1 ). For purposes of this document, operatively coupled means directly or indirectly connected or coupled.  FIG. 2  illustrates a pair of spaced stationary supports  32  operatively coupled to the front wall  18  of the container  10 . Each of the supports  32  do not move during the loading or unloading processes. Each support  32  is illustrated in the embodiment shown in  FIGS. 1-4  to be a guide eye, such as an eye bolt fixedly secured to a container wall. However, as shown in the alternative embodiments and described herein, these supports may assume other geometries or configurations. Although the drawings illustrate a pair of spaced supports  32  operatively coupled to each of the front and rear sides  18 ,  20  of the container  10 , any number of supports may be operatively coupled to the sides of the container. 
         [0053]    As shown in  FIG. 3 , each of the supports or guide eyes  32  extends through the container side structure and may be secured in place with a nut  34  and washers  36  on each side of the container side structure. 
         [0054]    As shown in  FIGS. 1-4 , container  10  further comprises two guides  40 . One of the guides  40  extends through an opening  38  through each of the supports or eye bolts  32  secured to the rear wall  20  of the container  10 . Similarly, as best shown in  FIG. 2 , the second guide  40  extends through an opening  38  of each of the supports or eye bolts  32  secured to the front wall  18  of the container  10 . As shown in  FIG. 3 , each of the guides  40  has a length greater than the width “W” of the interior  24  of the container  10 . Therefore, as shown in  FIGS. 3 and 4 , each guide  40  has opposed end portions  42  (only one being shown). As shown in  FIGS. 3 and 4 , each end portion  42  of each guide  40  extends into a bore  44  in one of the container side walls  16 . As shown in  FIGS. 3 and 4 , a washer  46  is located inside the container side wall  16  surrounding the guide  40 . As best shown in  FIG. 3 , a holder  48  in the form of a triangular metal wire has two ends  50  which fit into holes in the guide  40 . The holder  48  at each end of each guide  40  functions to hold each guide  40  in place. The pair of holders  48 , acting in concert, functions to prevent the guide  40  from separating from the container side walls  16 . As shown in  FIG. 3 , the holder  48  (shown on the left of the container) functions to prevent the guide  40  to which the holder  48  is secured from moving further to the left, such that the right side of the guide  40  separates from the opposite side wall  16 . The other guide  48  proximate the side wall  16  (shown on the right of the container) functions to prevent the guide  40  from moving to the right, such that the left side of the guide  40  separates from the opposite side wall  16 . Although one configuration of holder in the form of a triangular metal wire is shown and described, other types of holders, such as wires or pieces of other materials configured in other shapes, may be used. 
         [0055]    As shown in  FIG. 4 , each of the guides  40  are in the form of a tube having a hollow interior  52 . Although one configuration of guide in the form of a tube is shown and described, other types of guides, such as solid rods made of metal or plastic or wood, or any other desired material, may be used. 
         [0056]    As shown in  FIGS. 1-4 , container  10  further comprises a lower level of dunnage  54  which may be fixedly secured to the floor  22  of the container. This lower level of dunnage  54  comprises a pair of stationary dunnage components  56  spaced from one another. Each stationary dunnage component  56  has a plurality of spaced notches  58  extending downwardly from an upper surface of the dunnage component  56 . The notches  58  are for receiving and retaining products  60 , as shown in  FIG. 2 , one of the products  60  extending between a pair of corresponding notches  58  in the stationary dunnage component  56 . Although one specific shape of notch  58  is illustrated in the drawings, this document is not intended to limit in any way the size, shape or configuration of notches  58  in any of the dunnage components  56  of the lower level of dunnage  54 . If desired, more than two dunnage components may comprise the lower level of dunnage  54 . Alternatively, a single dunnage component or member may comprise the lower level of dunnage  54 . 
         [0057]    Although one specific shape of product  60  is illustrated in the drawings, this document is not intended to limit in any way the size, shape or configuration of product  60  shipped or stored in any of the embodiments described or shown herein. One type of product which may be used in accordance with the present invention is car fenders. 
         [0058]    As shown in  FIGS. 1-4 , container  10  further comprises an upper level of dunnage  62  which is movable inside the interior  24  of the container. This upper level of dunnage  62  comprises a pair of movable dunnage components  64  spaced from one another. Each of the movable dunnage components  64  moves between one of the container side walls  16  and one of the supports  32 . Each movable dunnage component  64  has a plurality of spaced notches  66  for receiving and retaining products  60 , as shown in  FIG. 6A . Although one specific shape of notch  66  is illustrated in the drawings, this document is not intended to limit in any way the size, shape or configuration of notches  66  in any of the dunnage components  64  of the upper level of dunnage  62 . 
         [0059]    As shown in  FIGS. 2-4 , each of the dunnage components  64  of the upper level of dunnage  62  has a main portion or body  65  having a pair of openings  68 , one on each end. The body  65  is commonly made of foam, but may be made of other materials. As best shown in  FIG. 4 , a sleeve  70  extends through each opening  68  in the dunnage body  65  of the dunnage component  64  and moves with the dunnage component  64 . Each sleeve  70  is sized to allow one of the guides  40  to extend through the sleeve  70 . If desired, the sleeves  70  may be omitted. 
         [0060]    As shown in  FIGS. 2-4 , each of the dunnage components  64  of the upper level of dunnage  62  also has a stiffener  72  and a liner  74 , the liner  74  being between the stiffener  72  and body  65  of dunnage component  64 . As best shown in  FIG. 4 , the stiffener  72  and liner  74  of the upper dunnage component  64  are each generally “U-shaped” and fit around a lower portion of the body or dunnage body  65  of upper dunnage component  64 . The stiffener  72  may be made of foam, metal and/or plastic and provides rigidity in two directions to the dunnage component  64 . The liner  74  may be made of metal and/or plastic and provides rigidity in two directions to the dunnage component  64 . As shown in  FIG. 3 , fasteners  76  secure the body  65  of upper dunnage component  64 , the liner  74  and stiffener  72  together. If desired, the stiffener  72  and/or liner  74  of the upper dunnage component  64  may be omitted. 
         [0061]      FIG. 5  illustrates an alternative upper dunnage component  64   a  comprising a body or main portion  65  having notches  66  identical to the main body portion  65  of upper dunnage component  64  of  FIGS. 1-4 . However, each upper dunnage component  64   a  has no generally “U-shaped” liner or stiffener at the bottom thereof. Instead upper dunnage component  64   a  has a stiffener  78  in the form of a block located inside the interior of the body  65  of upper dunnage component  64   a  and held therein by fastener  80 , as shown in  FIG. 5 . The stiffener  78  may be made of plastic, aluminum, steel, fiber, glass or any other stiffening material. Any of the dunnage components shown or described herein may be used in upper or lower levels of any embodiment of container shown or described herein. 
         [0062]      FIG. 3A  illustrates an upper dunnage component  114  which may be incorporated into any container in place of one of the dunnage components  64 . Each of the upper dunnage components  114  has notches  116  identical to the notches  66  of upper dunnage component  64 . However, each upper dunnage component  114  has no liner or stiffener. Each dunnage component  114  is a one-piece unitary body made of foam, rubber, wood or any other suitable material. These dunnage components  114  may be used in upper or lower levels of dunnage of any of the embodiments of container shown or described herein. Although one specific shape of notch  116  is illustrated in the drawings, this document is not intended to limit in any way the size, shape or configuration of notches  116  in any of the dunnage components  114  of the upper level of dunnage  62  or any of the levels of dunnage. 
         [0063]      FIG. 3B  illustrates an upper dunnage component  114   a  which may be incorporated into any container in place of one of the dunnage components  64  or dunnage components  114  shown in  FIG. 3A . Each of the upper dunnage components  114   a  has a specific geometry for a particular part or product, in this case, a plurality of spaced protrusions  118  between recesses or valleys  119 . The protrusions  118  may be configured or sized to fit into one or more recesses (not shown) of a product  60 ′, shown in dashed lines in  FIG. 3A , to reduce the likelihood of the product  60 ′ moving, shifting or separating from the dunnage and getting damaged during shipment. In other words, the specific configuration of the dunnage components may be shaped or configured to secure products in place so as to reduce the chances of the products getting damaged during shipment. Like upper dunnage component  114  shown in  FIG. 3A , each upper dunnage component  114   a  has no liner or stiffener. Each upper dunnage component  114   a  is a one-piece unitary body made of foam, rubber, wood or any other suitable material. These dunnage components  114   a  may be used in upper or lower levels of dunnage in any of the embodiments of container shown or described herein. Although one specific shape of protrusion  118  is illustrated in the drawings, this document is not intended to limit in any way the size, shape or configuration of protrusions  118  in any of the dunnage components  114   a  of the upper level of dunnage  62  or any of the levels of dunnage. If desired, the unitary dunnage component  114   a  shown in  FIG. 3B  may be incorporated into a dunnage component having one or more liners or stiffeners in accordance with the present invention. 
         [0064]      FIG. 3C  illustrates a dunnage component  114   b  which may be incorporated into any container in place of any of the dunnage components shown or described herein. Each of the dunnage components  114   b  may have a specific geometry for a particular part or product; in this case, a plurality of spaced protrusions  118  between recesses or valleys  119 . The protrusions  118  may be configured or sized to fit into one or more recesses (not shown) of a product  60 ′, shown in dashed lines in  FIG. 3C , to reduce the likelihood of the product  60 ′ moving, shifting or separating from the dunnage and getting damaged during shipment. In other words, the specific configuration of the dunnage components may be shaped or configured to secure products in place so as to reduce the chances of the products getting damaged during shipment. Unlike dunnage components  64 ,  114 ,  114   a  shown in  FIGS. 3 ,  3 A,  3 B, respectively, each dunnage component  114   b  has no opening therethrough. Instead, each dunnage component  114   b  comprises a one-piece unitary body made of foam, rubber, wood or any other suitable material to which is secured a sleeve  70  with a bracket  71  and fastener  73 . Although one type of bracket  71  is shown, any known bracket may be used. Similarly, although one particular sleeve  70  is illustrated, other types of sleeves may be used. Sleeve  70  is sized to allow one of the guides  40  to extend through the sleeve  70  regardless of whether the sleeve  70  is inside or outside the body of the dunnage component. These dunnage components  114   b  may be used in upper or lower levels of dunnage in any of the embodiments of container shown or described herein. Although one specific shape of protrusion  118  is illustrated in the drawings, this document is not intended to limit in any way the size, shape or configuration of protrusions  118  in any of the dunnage components  114   b . If desired, a sleeve and bracket-like sleeve  70  and bracket  71  may be incorporated into any of the dunnage components described or shown herein. For example, a dunnage component, like dunnage component  114  shown in  FIG. 3A , may lack an opening therein, the sleeve  70  being secured to the body of the dunnage component  114  with a bracket or via any other suitable manner. 
         [0065]      FIG. 3D  illustrates another dunnage component  114   c  which may be incorporated into any container in place of one of the dunnage components shown or described herein. Each upper dunnage component  114   c  has no opening therethrough. Instead, each upper dunnage component  114   c  comprises a one-piece unitary body made of foam, rubber, wood or any other suitable material to which is secured a slider  115  like those described and shown in U.S. Pat. No. 7,762,422, which is fully incorporated herein. Although one type of slider  115  is shown, any other shaped slider may be used. Slider  115  is sized to move along a track  117  like tracks shown in U.S. Pat. No. 7,762,422. These dunnage components  114   c  and tracks  117  may be used in upper or lower levels of dunnage in any of the embodiments of container shown or described herein. Although one specific shape of track  117  is illustrated in the drawings, this document is not intended to limit in any way the size, shape or configuration of tracks  117  in any of the levels of dunnage. If desired, the tracks  117  may be the full width of the interior of the container. 
         [0066]      FIGS. 6A-6C  illustrates a method of unloading product  60  from a fully loaded container  10 . The method comprises the first step of pulling product  60  extending between the two dunnage components  64  of the upper level or layer of dunnage  62  out of the dunnage in the direction of arrow  61 . As shown in  FIG. 6B , the two dunnage components  64  of the upper level or layer of dunnage  62  are then moved outwardly away from each other in the direction of arrows  63 . More specifically, an operator moves them from a first or closed position shown in  FIG. 6A  to a second or open position illustrated in  FIG. 6B . As shown in  FIG. 6B , when the two dunnage components  64  of the upper level of dunnage  62  are in their second or open position, the opening therebetween is greater than when they are in the first or closed position illustrated in  FIG. 6A . As shown in  FIG. 6C , the next step comprises removing product  60  extending between the dunnage components  56  of the lower level of dunnage  54 , the two dunnage components  64  of the upper level of dunnage  62  remaining in their second or open position. With the dunnage components  64  of the upper level of dunnage  62  being in their second or open position, products  60  in the lowermost level of dunnage  54  may be more easily removed from the container in the direction of arrow  67  without the dunnage components  64  of the upper level of dunnage  62  being in the way or obstructing the removal of the lower level of products though the opening. 
         [0067]      FIGS. 6D-6F  illustrates a method of loading product  60  into an empty container  10 . As shown in  FIG. 6D , products  60  are loaded into the container&#39;s interior  24  by the operator in the direction shown by arrow  82  between the dunnage components  64  of the upper level of dunnage  62  (which are in their open position). Thus, products  60  are loaded into the lower level of dunnage  54  and, more specifically, loaded such that each product  60  extends between the dunnage components  56  of the lower level of dunnage  54 . As shown in  FIG. 6E , once the lower level of dunnage  54  is full of product  60 , the two dunnage components  64  of the upper level or layer of dunnage  62  are then moved inwardly towards each other in the direction of arrows  84 . More specifically, an operator moves them from a second or open position shown in  FIG. 6D  to a first or closed position illustrated in  FIG. 6F . The distance they travel inwardly is limited by the location of the supports  32 . Each of the dunnage components  64  of the upper level of dunnage  62  does not travel between the supports  32 . In other words, each of the dunnage components  64  of the upper level of dunnage  62  does not travel inside the support  32  closest to it. As shown in  FIG. 6F , the last step of the method comprises loading product  60  into the upper level or layer of dunnage  62  in the direction of arrow  86 , each product  60  extending between the two dunnage components  64  of the upper level or layer of dunnage  62 . 
         [0068]    Although  FIGS. 6A-6F  illustrate methods of loading and unloading product into container  10  having two guides  40 , these methods may be used in any of the embodiments shown or described herein. For example, the upper components may be moved in the same manner using the container  10   a  having the shorter guides  40   a . Although one configuration of container is shown and described with respect to the method, the method may be practiced with any container shown or described herein. 
         [0069]      FIGS. 7 ,  8  and  9  illustrate an alternative embodiment of container  10   a . Container  10   a  is identical to container  10  except for the guides. Rather than having two guides  40 , each having a length greater than the width “W” of the interior  24  of the container  10 , container  10   a  has four guides  40   a . Two of the four guides  40   a  are front guides, and two are rear guides, each guide  40   a  being shorter in length than the width “W” of the interior  24  of the container  10   a . In this embodiment, one of the rear guides  40   a  extends between one of the side walls  20  and a support  32  operatively coupled to rear wall  20 . The other rear guide  40   a  extends between the other side wall  20  and the other support  32  operatively coupled to rear wall  20 . Similarly, as shown in  FIG. 8 , each of the front guides  40   a  extends from one of the container side walls  16  to the nearest support  32 . As shown in  FIG. 9 , each guide  40   a  extends through an opening  38  through one of the supports or eye bolts  32  operatively coupled to the front or rear wall  18 ,  20  of the container  10 . As shown in  FIG. 9 , each guide  40   a  has opposed end portions  42   a . As shown in  FIG. 9 , one end portion  42   a  of each guide  40   a  extends into a bore  44  in one of the container side walls  16 . As shown in  FIGS. 8 and 9 , a washer  46  is located inside the container side wall  16  surrounding the guide  40   a . A holder  48 , like the holder  48  shown in  FIG. 3 , is secured to the guide  40   a  inside the washer  46 . As best shown in  FIG. 9 , two holders  48  are secured to each guide  40   a . Each holder  48  is in the form of a triangular metal wire and has two ends  50  which fit into holes in the guide  40   a . The holders  48  function to hold each guide  40   a  in place. The pair of holders  48 , acting in concert, functions to prevent the guide  40  from separating from one of the container side walls  16  and from separating from one of the supports  32 . As shown in  FIG. 9 , the holder  48  (shown on the left of the container) functions to prevent the guide  40   a  from moving further to the left, such that the right side of the guide  40   a  separates from the nearest support  32 . The other guide  48  located inside the support  32  (shown on the right in  FIG. 9 ) functions to prevent the guide  40   a  from moving to the right, such that the left side of the guide  40   a  separates from the side wall  16 . 
         [0070]    As shown in  FIG. 9 , each of the guides  40   a  is in the form of a tube having a hollow interior  52   a . Although one configuration of guide in the form of a tube is shown and described, other types of guides, such as solid rods or beams made of metal or plastic or wood, or any other desired material, may be used if desired. 
         [0071]      FIGS. 10 ,  11 ,  12  and  13  illustrate an alternative embodiment of container  10   b . Container  10   b  is similar to container  10   a  and uses the same dunnage and same four guides  40   a . In this embodiment, two of the four supports  32   b  are operatively coupled to rear wall  20  below a removable section  88 . Although not shown, the other two of the four supports  32   b  are operatively coupled to front wall  18  below a removable section  88 . As shown in  FIG. 11 , each of the container walls may have a removable section or door  88 .  FIG. 11  illustrates the removable section  88  of rear wall  20  being removed in the direction of arrow  90 . Alternatively, one or more of the wall sections  88  may be hinged to the remainder of the container wall, side or side structure. 
         [0072]    As shown in  FIG. 12 , two of the four supports or brackets  32   b  are each operatively coupled with fasteners  92  to container rear wall  20  below the removable section  88  so as to not interfere with the removal of the wall section  88  of rear wall  20 . The other two supports  32   b  are operatively coupled to the front container wall  18  below the removable section  88  so as to not interfere with the removal of the wall section  88  of front wall  18 . As shown in  FIG. 12 , each of the supports  32   b  has a generally planar first portion  94  and a generally planar second portion  96  extending outwardly from the first portion  94 . As shown in  FIGS. 12 and 13 , the second portion  96  of each support or bracket  32   b  has a holder  98  on an outer surface thereof. Each holder  98  is sized to receive and retain one end of one of the guides  40   a , as best illustrated in  FIG. 12 . As shown in  FIGS. 12 and 13 , the other end of each guide  40   a  extends into an opening  100  in a flange  102  located in a bracket  104  secured to one of the container side walls  16 . As shown in  FIGS. 12 and 13 , fasteners  106  are used to secure the bracket  104  to one of the container side walls  16 . 
         [0073]      FIGS. 14-17  illustrate an alternative embodiment of container  10   c . Container  10   c  is similar to container  10   a  and uses the same dunnage and same four guides  40   a . However, in container  10   c , the supports  32   c  are not eye bolts. As best shown in  FIG. 15 , two of the four supports  32   c  are secured to rear wall  20 , and the other two of the four supports  32   c  are secured to front wall  18  in any conventional manner. 
         [0074]    As best shown in  FIGS. 16 and 17 , each of the supports  32   c  comprises a U-shaped bracket  108  secured with fasteners  110  to a middle body  112 . As best shown in  FIG. 17 , the U-shaped bracket  108  contacts three sides of the body  112 . As shown in  FIG. 17 , the guide  40   a  passes through an opening in one wall of the bracket  108  (the innermost wall) and through the body  112  of the support  32   c . Thus, each support  32   c  is sized to receive and retain one end of one of the guides  40   a , as best illustrated in  FIG. 17 . As shown in  FIGS. 16 and 17 , the other end of each guide  40   a  extends into a bore  44  in one of the container side walls  16 . As shown in  FIGS. 3 and 4 , a washer  46  is located inside the container side wall  16  surrounding the guide  40   a . As best shown in  FIG. 16 , a holder  48  in the form of a triangular metal wire has two ends  50  which fit into holes in the guide  40   a . The holder  48  at one end of each guide  40   a  functions to hold each guide  40   a  in place. The holder  48  helps prevent the guide  40   a  from moving to the left, as shown in  FIG. 16  and discussed herein. The other end of guide  40   a  passes through one of the sides of bracket  108  and through the body  112  of the support  32   c , abutting the opposed side of bracket  108 . 
         [0075]      FIGS. 18-19  illustrate an alternative embodiment of container  10   d . Container  10   d  is similar to container  10   c  shown in  FIGS. 14-17  in that container  10   d  uses the same dunnage, guides  40   a  and supports  32   c  as container  10   c . However, in container  10   d , the side structures are not solid walls. As best shown in  FIG. 18 , container  10   d  comprises an outer metal rack or frame  120  having a bottom  122  and four corner posts, two rear corner posts  124  and two front corner posts  126 . As best shown in  FIG. 19 , each of the corner posts  124  and  126  is generally rectangular in cross-section, has a hollow interior, and a knob  128  at the top thereof for stacking purposes so that multiple containers  10   d  may be stacked upon one another. The knobs  128  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. If desired, each of the corner posts may have a cap  130  at the bottom thereof (only one being shown in  FIG. 18 ). 
         [0076]    The metal frame  120  further comprises an upper rear member  132  and a lower rear member  134  (see  FIG. 19 ) extending between the two rear corner posts  124  and being secured thereto. Two spaced intermediate rear braces  136  extend between the upper and lower rear members  132 ,  134  and are secured thereto, such as by welding, for example. As shown in  FIG. 18 , two of the four supports  32   c  are welded or otherwise secured to the intermediate rear braces  136  (one support  32   c  per intermediate rear brace  136 ). The other two supports  32   c  are welded or otherwise secured to the vertical members  164  of the front gates  160  described below (one support  32   c  per vertical member  164 ). An intermediate rear panel  138  extends between the two rear corner posts  124  and is secured thereto. These rear members  132 ,  134 , rear panel  138  and rear corner posts  124  define a rear portion or structure  140  of the metal frame  120 , intermediate rear panel  138  being above lower rear member  134 . 
         [0077]    The metal frame  120  further comprises, on each side of the container, side members  142 ,  144  and  146  extending between one of the rear corner posts  124  and one of the front corner posts  126  and secured thereto. On each side, upper side member  142  is located above intermediate side member  144  and generally co-planar with the upper rear member  132 , as shown in  FIG. 18 . On each side, intermediate side member  144  is located above lower side member  146 , lower side member  146  being generally co-planar with the lower rear member  134 . As shown in  FIG. 18 , the four guides  40   a  are secured to the intermediate side members  144 , two per side. In addition, each side has a side panel  148  extending between and secured to one of the rear corner posts  124  and one of the front corner posts  126 . The side members  142 ,  144  and  146 , side panel  148  and corner posts  124 ,  126  define a side portion or structure  150  of the metal frame  120 . 
         [0078]    As best shown in  FIG. 19 , the bottom  122  of the metal rack  120  further comprises generally co-planar perimeter members defining a rectangle, including lower rear member  134 , two lower side members  146  and front floor member  152 . Front floor member  152  extends between the two front corner posts  126  and is secured to each of them. Bottom  122  of the metal rack  120  further comprises a plurality of intersecting interior members  154  extending between opposed perimeter members and secured thereto, members  154  comprising part of the bottom  122  of the metal rack  120 . Although four interior members  154  are shown in the bottom  122  of the metal rack  120 , any number of interior members may be used. Similarly, although the rear and side portions  140 ,  150  of the metal rack  120  are illustrated as having a certain number of braces or members extending between corner posts, any number of braces or members may extend between corner posts of any desired shape or size. 
         [0079]    A floor  156  rests on top of the bottom of the metal outer frame  120 . The floor  156  may be made of plastic, wood, metal or any other desired material. Although the floor  156  is illustrated as being one piece or panel, more than one piece or panel may comprise the floor  156  resting on top of the bottom  122  of the metal rack  120 . 
         [0080]    The metal frame  120  further comprises two front gates  160 , one on each side of the container  10   d . Each front gate  160  comprises a horizontal member  162  secured to one of the front corner posts  126  and being generally co-planar with the upper side members  142  and upper rear member  132 . Each front gate  160  further comprises a vertical member  164 , the horizontal member  162  and the front floor member  152 . 
         [0081]    Although the outer metal rack or frame  120  is shown only in  FIGS. 18 and 19  with guides  40   a  and supports  32   c , any of the dunnage systems shown or described herein may be used in a container having an outer metal rack or frame like the outer metal rack or frame  120 . 
         [0082]    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 example 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.

Technology Classification (CPC): 1