Abstract
A container for holding product therein during shipment and being returned for reuse has a base and opposed sides, linear and non-linear tracks, and a plurality of dunnage supports extending between the tracks. At least one of the tracks on each side may be non-linear in the shape of a C or U or J. One type of dunnage support comprises end members and a tubular middle member, the end members being movable along the tracks. The dunnage supports support dunnage, such as pouches.
Claims
1. A container for holding product therein during shipment, the container comprising: a base and two opposed sides; upper and lower tracks supported by each of the container sides, the upper track on each of the sides having an upper portion extending from front to back inside the container and a lower portion extending from front to back inside the container spaced below the upper portion, the upper and lower portions being joined by a connecting portion located at the front of the container; upper dunnage supports extending between the upper tracks and being movable along the upper tracks; an upper layer of dunnage supported by the upper dunnage supports; lower dunnage supports extending between the lower tracks and being movable along the lower tracks; a lower layer of dunnage supported by the lower dunnage supports; and a shelf assembly for moving the upper layer of dunnage once emptied.
2. The container of claim 1 wherein each side of the container has two tracks.
3. The container of claim 2 wherein each of the upper tracks is generally U-shaped.
4. The container of claim 1 wherein at least one of the tracks on each of the sides is linear.
5. The container of claim 1 wherein the container has at least two tracks on each of the sides, at least one of the tracks being linear.
6. The container of claim 5 wherein each of the upper tracks has an inhibitor to aid in maintaining the dunnage supports in an upper level of the upper track.
7. The container of claim 6 wherein each of the inhibitors comprises a bump.
8. The container of claim 1 wherein the dunnage comprises pouches.
9. The container of claim 1 wherein the base and sides are part of a metal frame.
10. A container for holding product therein during shipment, the container comprising: a base and opposed sides; first and second tracks supported by each of the opposed sides, the first track on each side having an upper portion extending from front to back inside the container proximate an upper edge of the container and a lower portion extending from front to back inside the container spaced below the upper portion, the upper and lower portions being joined by a connecting portion located at the front of the container; a plurality of dunnage supports extending between opposed tracks and being movable along corresponding tracks; pouches supported by the dunnage supports; a movable shelf assembly between the first and second tracks for moving emptied pouches.
11. The container of claim 10 wherein each of the dunnage supports comprises a pair of end members and a middle member extending between the end members.
12. The container of claim 10 further comprising metal straps on each side of the container, each of the tracks on each side of the container being secured to the metal straps.
13. The container of claim 10 wherein each side of the container has two tracks, a non-linear track and a linear track.
14. The container of claim 13 wherein each non-linear track is generally U-shaped.
15. The container of claim 13 wherein each of the non-linear tracks has an inhibitor to aid in maintaining the dunnage supports in an upper level of the non-linear track.
16. The container of claim 10 wherein the base and sides are part of a metal frame.
17. A container for holding product therein during shipment, the container comprising: a base and opposed sides; tracks supported by each side of the container at different levels, an uppermost track on each side having an upper portion extending from front to back inside the container proximate an upper edge of the container and a lower portion extending from front to back inside the container spaced apart from the upper portion, the upper and lower portions being joined by a connecting portion located at the front of the container; a plurality of dunnage supports movable along the tracks; pouches supported by the dunnage supports; and a shelf assembly for moving emptied pouches.
18. The container of claim 17 wherein each side of the container has at least one linear track.
19. The container of claim 17 wherein each of the generally U-shaped tracks has an inhibitor to aid in maintaining the dunnage supports in an upper level of the track.
20. The container of claim 17 wherein each side of the container has a linear track, the generally U-shaped track being above the linear track.
21. The container of claim 17 wherein the base and sides are part of a metal frame.
22. The container of claim 17 wherein each of the dunnage supports comprises end members movable along corresponding tracks and a middle member extending between the end members.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) 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.
(2) FIG. 1 is a perspective view of one embodiment of a reusable and returnable container;
(3) FIG. 1A is a perspective view of the container of FIG. 1 without the dunnage and dunnage supports;
(4) FIG. 1B is an enlarged perspective view of a portion of the container of FIG. 1 without some of the dunnage and dunnage supports;
(5) FIG. 1C is an enlarged view of the encircled area 10 of FIG. 1;
(6) FIG. 1D is a cross-sectional view taken along the line 1D-1D of FIG. 10;
(7) FIG. 2 is a cross-sectional view taken along the line 2-2 of FIG. 1;
(8) FIG. 3A is a cross-sectional view of a portion of the container of FIG. 1, showing the front product of an upper layer of products being removed;
(9) FIG. 3B is a cross-sectional view of a portion of the container of FIG. 1, showing the rear product of the upper layer of products being removed;
(10) FIG. 3C is a cross-sectional view of a portion of the container of FIG. 1, showing the upper layer of dunnage being pushed rearwardly;
(11) FIG. 3D is a cross-sectional view of a portion of the container of FIG. 1, showing the front product of the lower layer of products being removed;
(12) FIG. 3E is a cross-sectional view of a portion of the container of FIG. 1, showing the rear product of the lower layer of products being removed;
(13) FIG. 3F is a cross-sectional view of a portion of the container of FIG. 1, showing both layers of dunnage emptied;
(14) FIG. 4A is a cross-sectional view of a portion of the container of FIG. 1, showing a product being inserted into a rear pouch of the lower layer of dunnage;
(15) FIG. 4B is a cross-sectional view of a portion of the container of FIG. 1, showing a product being inserted into a front pouch of the lower layer of dunnage;
(16) FIG. 4C is a cross-sectional view of a portion of the container of FIG. 1, showing the upper layer of dunnage being moved forwardly;
(17) FIG. 4D is a cross-sectional view of a portion of the container of FIG. 1, showing a product being inserted into a rear pouch of the upper layer of dunnage;
(18) FIG. 4E is a cross-sectional view of a portion of the container of FIG. 1, showing another product being inserted into a front pouch of the upper layer of dunnage;
(19) FIG. 4F is a cross-sectional view of a portion of the container of FIG. 1, showing each of the pouches of the upper layer of dunnage containing a product;
(20) FIG. 5A is a cross-sectional view of a portion of an alternative embodiment of container, having a two-piece shelf between the upper and lower levels of dunnage, the shelf being in an extended position;
(21) FIG. 5B is a cross-sectional view of a portion of the container of FIG. 5A, showing the shelf in a contracted position;
(22) FIG. 6 is a perspective view of another embodiment of a reusable and returnable container;
(23) FIG. 7 is a cross-sectional view taken along the line 7-7 of FIG. 6;
(24) FIG. 8 is an enlarged view of the encircled area 8 of FIG. 6;
(25) FIG. 9 is a cross-sectional view taken along the line 9-9 of FIG. 8; and
(26) FIG. 10 is a cross-sectional view taken along the line 10-10 of FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
(27) 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 an outer metal frame 12 having a base 14, two rear corner posts 16 and two front corner posts 18, all four corner posts 16, 18 extending upwardly from the base 14.
(28) As best shown in FIG. 1A, the base 14 is generally rectangular in shape and comprises a front perimeter member 20, a rear perimeter member 22 and two side perimeter members 24. The perimeter members of the base 14 may be secured together or secured to the corner posts 16, 18 via any conventional means, including welding. As best shown in FIG. 1A, two rectangular openings 26 extend through each of the base perimeter members 20, 22 and 24, each opening 26 communicating with the hollow interior of one of the intersecting interior members 28.
(29) As best shown in FIG. 1A, the base 14 of the container 10 further comprises a plurality of intersecting interior members 28 extending between opposed perimeter base members 20, 22 and 24 and secured thereto, interior members 28 comprising part of the base 14 of the rack 12. Although four interior members 28 are shown in the base 14 of the container 10, any number of interior members may be used. Each of the interior members 28 of the base 14 is generally rectangular in cross-section and has a hollow interior ending in openings 26 of the perimeter base members 20, 22 and 24.
(30) As best shown in FIG. 2, each of the corner posts 16 and 18 is generally rectangular in cross-section, has a hollow interior, and a knob 30 at the top thereof for stacking purposes so that multiple containers 10 may be stacked upon one another. The knobs 30 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.
(31) The frame 12 further comprises an upper rear member 32 extending between the two rear corner posts 16 and is secured thereto. The frame 12 further comprises, on each side of the container, an upper side member 34 and three side panels 36, 38, 40, the side panels being vertically spaced from each other. Each of the side panels 36, 38 and 40 extends between one of the rear corner posts 16 and one of the front corner posts 18 and is secured thereto. On each side, upper side panel 36 is located above middle side panel 38, which is located above lower side panel 40. The two upper side members 34 are generally co-planar with the upper rear member 32.
(32) Although one configuration of frame is illustrated, the present invention may be used with other types or configurations of frames.
(33) As best shown in FIG. 1A, container 10 further comprises a plurality of generally vertically oriented spaced straps 42 secured to the upper and middle side panels 34, 36 with fasteners 44 on each side of container 10. Although the drawings show three straps 42 on each side of the container, any number of straps may be used on each side of the container. The straps 42 may be made of metal or any other desired material and may be secured to the container via any known method, including welding.
(34) As shown in FIG. 1A, a stationary generally U-shaped track 46 is secured to the straps 42 on each side of the container 10 in any desired manner, such as welding, for example. The generally U-shaped track 46 comprises stationary generally horizontally oriented upper and lower portions 48, 50, respectively, vertically spaced apart from each other at different levels. A connecting portion 52 joins the upper and lower linear portions 48, 50, respectively, of the generally U-shaped track 46 on each side of the container. The upper and lower portions 48, 50 of generally U-shaped track 46 are generally parallel to each other. The connecting portion 52 of the generally U-shaped track 46 comprises a cut-out or pathway through a one-piece generally vertically oriented member 54. The connecting member 54 is shown secured to the upper and middle side panels 34, 36 with fasteners 56 on each side of container 10. However, it may be secured in place in any known manner, such as welding, for example. As best shown in FIG. 1B, the connecting portion 52 of the generally U-shaped track 46 has an inhibitor or bump or curved upper portion 58 located at the intersection of the connecting portion 52 and upper portion 48 to aid in keeping the dunnage supports 74a-74c in the upper portion 48 of the generally U-shaped track 46, as shown in FIG. 2.
(35) On each side of the container 10, a stationary linear lower track 60 is spaced below the lower linear portion 50 of the generally U-shaped track 46. As shown in FIG. 2, each linear lower track 60 has a greater length than the upper and lower linear portions 48, 50, respectively, of each of the generally U-shaped tracks 46. As shown in FIG. 1B, the linear lower track 60 is below the connecting member 54 when the container is in its position shown in FIG. 1. For purposes of this document, the description of the positioning of various components is described with respect to the container 10 being in the position illustrated in FIG. 1.
(36) Each generally U-shaped track 46 and each lower track 60 is fixed in a stationary position on one side of the container. The tracks are arranged in corresponding pairs at the same vertical levels. Each track may be one-piece or multiple pieces. Although the drawings disclose one generally U-shaped track 46 and one linear track 60 on each side of the container, the container may have any number of different levels or layers of tracks. As best shown in FIG. 10, each of the straight upper and lower portions 48, 50, respectively, of the generally U-shaped track 46, along with the lower linear track 60, may have an opening therein covered with a cover.
(37) As best shown in FIG. 10, each of the straight upper and lower portions 48, 50, respectively, of each generally U-shaped track 46, along with each lower linear track 60 has an upper wall 62, a lower wall 64 joined to the upper wall 62 by a side wall 66, and a lip 68 extending downwardly from the upper wall 62 and another lip 70 extending upwardly from the lower wall 64 defining an interior 72 of the upper portion of generally U-shaped track 46.
(38) Referring to FIG. 1, container 10 further comprises a plurality of dunnage supports 74a-74c, each dunnage support 74a-74c extending between the upper linear portions 48 of the generally U-shaped track 46 at the same level on opposed sides of the container. As shown in FIG. 2, container 10 further comprises a plurality of dunnage supports 74d-74f, each dunnage support 74d-74f extending between the tracks 60 at the same level on opposed sides of the container.
(39) As shown in FIG. 10, dunnage support 74b, along with each of the other dunnage supports, includes a pair of end members 76 and a tubular middle member 78 having a hollow interior 80 extending therebetween. The end members 76 are preferably made of injection molded plastic, such as nylon, but may be made of any other material. The tubular middle member 78 is preferably made of metal, but may be made of other suitable material, such as plastic.
(40) As shown in FIG. 1C, each end member 76 preferably has a first portion 82 having an X-shaped cross-sectional configuration and a second portion 84 having a circular cross-sectional configuration. Although one configuration of end member 76 is illustrated, any type or configuration of end member may be used with the present invention. In this embodiment, each end member 76 has a pair of heads 86, 88 at the end of the end member 76. Head 86 is furthest from the first portion 82 of the end member 76, and head 88 is spaced inwardly from head 86. The heads 86, 88 are spaced from one another to define a groove 90 therebetween which receives and retains the lips 68, 70 of either the generally U-shaped track 46 or the lower linear track 60. As shown in FIG. 10, head 86 is located inside the interior 72 of either the generally U-shaped track 46 or the lower linear track 60, and head 88 is located outside the interior 72 of either the generally U-shaped track 46 or the lower linear track 60. Head 86 keeps the end member 74 engaged with the track, while head 88 keeps the dunnage material out of the interior 72 of the track, thereby ensuring that the end members 76 may move smoothly along either the generally U-shaped track 46 or the lower linear track 60. Although one configuration of 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.
(41) As shown in FIG. 1D, each end of tubular middle member 78 fits over at least one portion 84 of an end member 76. An end surface 92 of tubular middle member 78 abuts head 88 of end member 76. Each end member 76 of each dunnage support 74a-74f is adapted to engage and move along one of the tracks. The end members 76 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.
(42) As best shown in FIG. 1D, dunnage support 74b, along with each of the other dunnage supports, includes a pair of end members 76 (only one being shown in FIG. 1D). Each end member 76 has a groove 94 formed in a portion 84 therein. Dunnage support 74b, along with each of the other dunnage supports, further includes a tubular middle member 78 having a hollow interior 80 extending therebetween. As shown in FIG. 1C, each end of tubular middle member 78 fits over at least one portion 82 of an end member 76. An end surface 92 of tubular middle member 78 abuts head 88 of end member 76. The tubular support or middle member 78 is preferably made of metal, but may be made of other suitable material, such as plastic. As shown in FIG. 1D, tubular middle member 78 has two detents 96 therethrough (one at each end) in which the material of the tubular middle member 78 is pressed downwardly into the groove 94. This attachment between each of the two end members 76 and the tubular middle member 78 enables some movement therebetween. Such interaction between the end members 76 and tubular middle member 78 allows for a tolerance of approximately one-quarter inch on each side. The detents 96 prevent separation of the tubular middle member 78 from the end members 76 while allowing some movement therebetween as the detents 96 move within the grooves 94 formed in the end members 76.
(43) FIG. 1C illustrates a dunnage support 74b used to support one side of one of the pouches. However, FIG. 10 illustrates another innovative feature or aspect of the invention. Upper portion 48 of generally U-shaped track 46 has an opening or cut-out 98 formed therein. Holes 100 are formed in the upper wall 62 of the upper portion 48 of generally U-shaped track 46, which are sized and threaded to receive fasteners 102. Although fasteners 102 are illustrated to be screws, they may be any other desirable fastener. A cap 104 is removably secured to the upper portion 48 of generally U-shaped track 46 to cover the opening or cut-out 98 formed in upper portion 48 of generally U-shaped track 46. As best seen in FIG. 10, cap 104 has a generally inverted U-shaped cross-sectional configuration, including a top portion 106 and side portions 108 extending downwardly from the top portion 106. Holes 110 are formed through the top portion 106 of the cap 104 and sized to receive fasteners 102, as shown in FIG. 10. The fasteners 102 are adapted to pass through the holes 110 in the cap 104 and into the holes 100 in the upper wall 62 of the upper portion 48 of generally U-shaped track 46. Caps of alternative shapes or sizes may be used if desired.
(44) When one of the end members 76, or any part of any of the dunnage supports is damaged or needs to be replaced for any reason, one may remove cap 104 after loosening fasteners 102, thereby exposing the opening or cut-out 98 of the upper portion 48 of generally U-shaped track 46. The damaged dunnage support may then be removed or inserted as necessary to repair or replace the damaged part or parts. The lower linear track 60, or any track described or illustrated herein, may have the same cut-out and cap for the same purpose.
(45) As best shown in FIG. 2, container 10 comprises two layers or levels 112a-112b of vertically spaced dunnage 114, each level being in the form of a plurality of pouches 116, and are suspended by and supported by a plurality of dunnage supports. Each pouch 116 has a front wall 118, a rear wall 120, a bottom 122 and two side walls 124 extending therebetween. In some applications, the side walls 124 may be omitted. As shown in FIG. 2, the top of the front wall 118 is attached to one of the dunnage supports, and the rear wall 120 is attached to an adjacent dunnage support. Although the dunnage 114, as shown, comprises pouches, the dunnage may assume other shapes or configurations. A pouch 116 is supported by two adjacent dunnage supports. As shown in FIG. 1C, the fabric of the pouch 116 is sewn or otherwise secured together along a seam 126 to make a pocket 128 in which is located a tubular middle member 78 of the dunnage support.
(46) Dunnage supports supporting pouches 116 are adapted to move from back to front inside the interior of the container 10, the end members 76 of the dunnage supports moving along the stationary tracks 46, 60.
(47) Multiple pouches 116 are shown being formed or created from one piece of material draped or laying over and secured to the dunnage supports. Alternatively, each pouch 116 may be made from its own piece of material, in which case, the pouches 116 would not be interconnected other than via the straps or space limiters (not shown).
(48) FIGS. 3A-3E illustrate a method of unloading product 5 from the pouches 116 of the container 10. This unloading method comprises the first step of moving the front dunnage support 74a of the three dunnage supports 74a-74c extending between the upper portions 48 of generally U-shaped tracks 46 from its position shown in FIG. 2 over the stops or curved portions or bumps 58 of the generally U-shaped tracks 46 and into the connecting portions 52 of the generally U-shaped tracks 46 to a position shown in FIG. 3A. As shown in FIG. 3A, the next step comprises removing the front product 5 (closest to the front of the container) out of its dunnage pouch 116 in the upper or top level of dunnage 112a in the direction of arrow 130.
(49) As shown in FIG. 3A, when dunnage support 74a is located extending between the bottoms of the connecting portions 52 of the generally U-shaped tracks 46, and dunnage support 74b is located extending between the upper portions 52 of the generally U-shaped tracks 46, an operator may easily remove a product inside the front pouch 116 because the dunnage support 74a is below dunnage support 74b. As shown in FIG. 3B, this is also true as regards dunnage supports 74b and 74c when an operator is unloading a second product 5 of the upper layer of dunnage. This orientation of the dunnage supports, due to the configuration of the U-shaped tracks 46, helps an operator from an ergonomic standpoint, reducing the stress and strain on the body of the operator when unloading product from the upper layer or level of dunnage. Thus, the unique configuration of the upper generally U-shaped tracks 46 inside the container 10 may reduce the container owner's costs because workers or operators may have fewer injuries/days off due to injury.
(50) As shown in FIG. 3B, the next step comprises moving dunnage support 74b (second from the front) from its position extending between the upper portions 48 of the generally U-shaped tracks 46 (shown in FIG. 3A) over the stops or curved portions or bumps 58 of the generally U-shaped tracks 46 and into the connecting portions 52 of the generally U-shaped tracks 46. In addition, dunnage support 74a is moved from its position shown in FIG. 3A extending between the connecting portions 52 of generally U-shaped tracks 46 to a position shown in FIG. 3B extending between the lower portions 50 of the generally U-shaped tracks 46. During this step, dunnage support 74a moves toward the rear of the container, the end members 76 of dunnage support 74a moving along the lower portions 50 of the generally U-shaped tracks 46.
(51) As shown in FIG. 3B, the next step comprises removing another product 5 from the other pouch 116 of the upper or top level of dunnage 112a in the direction of arrow 132. In the event the upper level of dunnage 112a has more than two pouches and three associated dunnage supports, each time a product 5 is removed from a pouch 116 of the upper level of dunnage 112a, the dunnage supports and associated dunnage are moved along the generally U-shaped tracks 46 in a generally counter-clockwise direction, as shown in FIG. 3A-3C. During this unloading process, the end members 76 at the ends of the dunnage supports move along the generally U-shaped tracks 46, as shown in FIGS. 3A-3C.
(52) As shown in FIG. 3C, once all of the products 5 in the pouches 116 of the top level of dunnage 112a have been removed, the operator moves the dunnage supports 74a-74c along with associated empty pouches 116 of the top level of dunnage 112a rearwardly along the lower portions 50 of generally U-shaped tracks 46 in the direction shown by arrows 134 to a resting position on top of a stationary shelf 135. FIG. 1A shows the stationary shelf 135 secured to the straps 42 and extending therebetween. After all the products 5 have been removed from the top level of dunnage 112a and the dunnage 112a is stored on top of stationary shelf 135, as shown in FIG. 3C, dunnage support 74a, which was originally the front dunnage support of upper dunnage supports 74a-74c, is now the rear dunnage support extending between the lower portions 50 of the generally U-shaped tracks 46.
(53) As shown in FIG. 3D, the process of unloading products 5 from container 10 is continued by an operator one level at a time moving downwardly. FIG. 3D shows a product 5 being removed from a front pouch 116 of the second lowest level of dunnage 112b in the direction of arrow 136. As shown in FIG. 3E, the next step comprises removing another product 5 from the rear pouch 116 of the bottom or lower level of dunnage 112b in the direction of arrow 138. When all of the products 5 of lower level 112b are removed, the container may be shipped to its desired destination. In the event the container has more than two levels, this process of removing products is repeated one layer or level at a time, each time all the products 5 are removed from the pouches 116 of a level, and each of the dunnage supports are pushed rearwardly to a rear portion of the container, creating open space for the operator to remove products from the next lowest level.
(54) FIG. 3F 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. During the unloading and loading processes, the upper and lower tracks 46, 60, respectively, remain stationary fixedly secured to the container 10. The dunnage supports 74a-74f and dunnage 114 hanging from the dunnage supports move inside the container with the assistance of an operator during the loading and unloading processes.
(55) FIGS. 4A-4F illustrate a method of loading product 5 into the pouches 116 of emptied container 10. As shown in FIG. 4A, the first step of the loading process comprises loading a product 5 into rear pouch 116 (furthest away from the front of the container) of the bottom level of dunnage 112b in the direction of arrow 140.
(56) As shown in FIG. 4B, the next step comprises moving dunnage supports 74e and 74f supporting the loaded pouch 116 of the bottom level 112b towards the rear of the container, the end members 76 of dunnage supports 74e and 74f moving along the tracks 60, the loaded rear pouch 116 containing a product 5. FIG. 4B illustrates an operator (not shown) loading a product 5 into front pouch 116 (closest to the front of the container) of the bottom level of dunnage 112b in the direction of arrow 141. In the event the bottom level 112b of dunnage has more than two pouches, the process of loading one pouch at a time of the bottom level 112b continues until each pouch of the bottom level 112b is full.
(57) As shown in FIG. 4C, after the bottom level 112b of dunnage is full, the empty pouches 116 of the upper level 112a of dunnage are moved or pulled toward the front of the container in the direction of arrows 142, the dunnage supports 74a-74c move forwardly along the lower portions 50 of the generally U-shaped tracks 46.
(58) As shown in FIG. 4D, the next step comprises inserting another product 5 into the rear pouch 116 of the upper level of dunnage 112a in the direction of arrow 144. As shown in FIG. 4D, when the dunnage support 74c is in a position extending between the upper portions 48 of generally U-shaped tracks 46, and the dunnage support 74b is in a position extending between the connecting portions 52 of generally U-shaped tracks 46, the first product 5 is inserted into the back or rear pouch 116 of the upper layer or level 112a of pouches 116.
(59) As shown in FIG. 4E, the next step comprises raising dunnage support 74b extending between the connecting portions 52 of generally U-shaped tracks 46, over the bumps 58 of the generally U-shaped tracks 46 and rearwardly along the upper portions 48 of generally U-shaped tracks 46 to a position shown in FIG. 4E, the loaded rear pouch 116 supported by dunnage supports 74b and 74c moving rearwardly. Once the dunnage supports 74a-74c are in their positions illustrated in FIG. 4E, the operator (not shown) inserts another product 5 into the front pouch 116 of the upper level of dunnage 112a in the direction of arrow 146. In the event the upper level of dunnage contains more than the two pouches shown, this process may be repeated. Each time a product 5 is inserted into a dunnage pouch 116 of the upper level of dunnage 112a, the dunnage supports 74a-74c are moved rearwardly with the pouches 116 containing product 5, the end members 76 at the ends of the dunnage supports moving along the generally U-shaped tracks 46.
(60) As shown in FIG. 4D, when dunnage support 74b is located extending between the bottoms of the connecting portions 52 of the generally U-shaped tracks 46, and dunnage support 74c is located extending between the upper portions 48 of the generally U-shaped tracks 46, an operator may easily insert a product 5 inside the rear pouch 116 because the dunnage support 74b is below dunnage support 74c. As shown in FIG. 4E, this is also true when dunnage support 74a is below dunnage support 74b when an operator is loading a product 5 into the front pouch of the upper layer of dunnage. This orientation of the dunnage supports, due to the configuration of the U-shaped tracks 46, helps an operator from an ergonomic standpoint, reducing the stress and strain on the body of the operator when loading product into the upper layer or level 112a of dunnage 114. Thus, the unique configuration of the upper generally U-shaped tracks 46 inside the container 10 may reduce the container owner's costs because workers or operators may have fewer injuries/days off due to injury.
(61) As shown in FIG. 4F, once all of the pouches 116 of the upper level of dunnage 112a have been loaded with product 5, and the dunnage supports 74a-74c extend between the upper portions 48 of generally U-shaped tracks 46 behind the curved bumps 58, the full container may be shipped to its desired destination. In the event the container has more than two levels or layers, the process of loading product 5 is continued by an operator one level at a time, moving upwardly until the container is full of product 5.
(62) Although one specific shape of product 5 is illustrated in the drawings, this document is not intended to limit in any way the size, shape or configuration of product 5 shipped or stored in any of the embodiments described or shown herein.
(63) FIGS. 5A and 5B illustrate an alternative embodiment of container 10a. Container 10a is identical to container 10, except for the shelf. Container 10a has a two-piece shelf assembly 150 having two pieces 152, 154, while the container 10 has only one stationary piece 135. Shelf assembly 150 comprises a front movable piece 152 and a rear stationary piece 154 located immediately above the lower track 60, as shown in FIGS. 5A and 5B. The loading and unloading processes described herein are identical in both containers, except that in container 10a, the front piece 152 of shelf assembly 150 may be moved from a first position shown in FIG. 5A to a second position shown in FIG. 5B. At least one bumper 156 is attached to the front of the first piece 152 of shelf assembly 150. As shown in FIG. 5B, the bumper(s) 156 helps push or move the empty dunnage rearwardly after the upper layer of dunnage has been emptied, as shown in FIG. 5B.
(64) FIGS. 6-11 illustrate another embodiment of reusable and returnable container 10b. The reusable and returnable container 10b, as shown, comprises a base 160, two sides 162 and a rear 164, each extending upwardly from base 160. The base 160 has openings therein 165 adapted to receive portions of a forklift (not shown) for purposes of lifting and moving the container 10b. Container 10b may further comprise a door assembly (not shown) at the front of the container, which may be any of the door assemblies disclosed in U.S. patent application Ser. No. 13/896,675 or pending U.S. patent application Ser. No. 13/975,682, each application of which is fully incorporated herein.
(65) As best shown in FIG. 7, container 10b further comprises a plurality of generally vertically oriented spaced straps 42b secured to each of the sides 162 with fasteners 44b on each side of the container. Although the drawings show two straps 42b on each side of the container, any number of straps may be used on each side of the container. The straps 42b may be made of metal or any other desired material.
(66) As shown in FIG. 7, a stationary generally U-shaped track 46b is secured to the straps 42b on each side of the container 10 in any desired manner, such as welding, for example. In some applications, the straps may be omitted and the stationary generally U-shaped track 46b secured directly to each side wall of the container 10 in any desired manner, such as with fasteners, for example. The generally U-shaped track 46b comprises stationary generally horizontally oriented upper and lower portions 48b, 50b, respectively, vertically spaced apart from each other at different levels and generally parallel to each other. A connecting portion 52b joins front portions of the upper and lower linear portions 48b, 50b, respectively, of the generally U-shaped track 46b on each side of the container. The generally U-shaped track 46b may be made of one piece or multiple pieces, welded or otherwise secured together. The generally U-shaped track 46b is welded or otherwise secured to the straps 42b on each side of container 10. However, it may be secured in place in any known manner. Although not shown, the upper portion 48b of the generally U-shaped track 46b may have an inhibitor or bump or curved upper portion located at the front thereof to aid in maintaining the dunnage supports in the upper portion 48b of the generally U-shaped track 46b during shipment, like the one shown in FIG. 1B.
(67) On each side of the container 10b, a stationary linear lower track 60b is spaced below the lower linear portion 50b of the generally U-shaped track 46b. On each side of the container, stationary linear lower track 60b is welded or otherwise secured to the straps 42b. As shown in FIG. 7, each linear lower track 60b may have a greater length than the upper and lower linear portions 48b, 50b, respectively, of each of the generally U-shaped tracks 46b. As shown in FIG. 7, the linear lower track 60b is below the generally U-shaped track 46b when the container is in its position shown in FIG. 7. For purposes of this document, the description of the positioning of various components is described with respect to the container 10b being in the position illustrated in FIG. 7.
(68) Each generally U-shaped track 46b and each lower track 60b is fixed in a stationary position on one side of the container because each track is welded or otherwise secured to multiple straps 42b. The tracks are arranged in corresponding pairs at the same vertical levels. Each track may be one-piece or multiple pieces. Although the drawings disclose one generally U-shaped track 46b and one linear track 60b welded or otherwise secured to the straps 42b on each side of the container, the container may have any number of different levels or layers of tracks. As best shown in FIG. 10, each of the straight upper and lower portions 48b, 50b, respectively, of the generally U-shaped track 46b, and/or the lower linear track 60b may have an opening therein covered with a cover.
(69) As shown in FIGS. 8 and 10, upper and lower linear portions 48b, 50b of each generally U-shaped track 46b and each linear track 60b have a generally C-shape in cross-section. Each track 60 or generally U-shaped track 46b, including any track portion 48b, 50b, has a back 66b, an upper wall 62b and a lower wall 64b each extending outwardly from the back 66b. As shown in FIG. 8, track portion 48b further comprises a lower lip 70b extending upwardly from the inner edge of the lower wall 64b and an upper lip 68b extending downwardly from the inner edge of the upper wall 62b. Although not shown, any of the tracks or track portions shown or described herein may have an alternative configuration, such as those disclosed in U.S. patent application Ser. No. 13/225,835, which is fully incorporated herein.
(70) Referring to FIGS. 6 and 7, container 10b further comprises a plurality of dunnage supports 168, each dunnage support 168 extending between the upper linear portions 48b of the generally U-shaped tracks 46b at the same level on opposed sides of the container. As shown in FIG. 7, container 10b further comprises a plurality of additional dunnage supports 168, each additional dunnage support 168 extending between the tracks 60b at the same level on opposed sides of the container.
(71) FIG. 7 illustrates two levels of dunnage supports 168, each dunnage support 168 being a unitary member and extending between a pair of tracks at the same level or height. The tracks 46b, 60 support the weight of the dunnage supports 168 and associated dunnage 170, as described below. FIGS. 8 and 10 illustrate a portion of one of the dunnage supports 168. Dunnage supports or cross members 168 may be made of metal or plastic, such as polyvinyl chloride, known as PVC. As shown in FIG. 10, each dunnage support 168 has a wall 172 of a thickness T and a hollow interior 174. As best shown in FIGS. 8 and 10, each dunnage support 168 at each end has two notches or cut-outs 176 located in an end portion 178 (only one being shown). The lips 68b, 70b of one of the tracks or track portions reside inside the notches 176 of one of the dunnage supports 168, as shown in FIG. 10, enabling the dunnage support 168 to move or slide thereon. Each notch 176 is sized to reside on and engage one of the tracks or track portions. See FIGS. 8 and 10. A portion of the end portion 178 of each dunnage support 168 resides inside the interior of one of the tracks or track portions and moves therein upon movement of the dunnage support 168. Each notch or cut-out may be any desired configuration and is not intended to be limited by the drawings of this document. Similarly, the location and number of notches or cut-outs of each dunnage support is not intended to be limited by the drawings of this document. For example, one of the notches may be omitted, as disclosed in U.S. patent application Ser. No. 13/225,835, which is fully incorporated herein.
(72) The dunnage 170 of each level or layer may comprise one or more pieces of dunnage material. In one embodiment, one piece of dunnage material is used for one level or layer of dunnage 70. However, multiple pieces of material may be used in one or more levels or layers of dunnage. The material may be a textile material, such as polyester. However, this document is not intended to limit the material of the dunnage.
(73) The drawings show the dunnage 170 supported by the dunnage supports 168 being in the form of pouches 180, each level having its own level of pouches. Two adjacent dunnage supports 168 support a pouch 180 having two sides 184 joined together with a bottom portion 186, as shown in FIG. 7. Each level of pouches 180 may be made from one piece of material or multiple pieces of material. As best shown in FIG. 8, the dunnage 170 or pouches 180 at each level may be supported by the dunnage supports 168. As shown in FIG. 8, the fabric of the pouch 180 is sewn or otherwise secured together along a seam 182 to make a pocket 188 in which is located one of the dunnage supports 168. Alternatively, each dunnage support 168 may comprise multiple pieces joined together as shown in the drawings and described herein.
(74) As best shown in FIG. 7, container 10b has a two-piece shelf assembly 150 having two pieces 152, 154 and two bumpers 156 attached to the front of the first piece 152 of shelf assembly 150. Shelf assembly 150 works as described above with respect to container 10a, and may be used in any container described or illustrated herein.
(75) FIG. 7 illustrates each pouch 180 containing a product 5b. Although one specific shape of product 5b is illustrated in the drawings, this document is not intended to limit in any way the size, shape or configuration of product 5b shipped or stored in any of the embodiments described or shown herein.
(76) 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's general inventive concept.
