U.S. patent application number 15/278718 was filed with the patent office on 2017-01-19 for container having dunnage components movable in opposite directions and method of using same.
The applicant listed for this patent is Bradford Company. Invention is credited to Donald J. Bazany, Judson A. Bradford, Timothy A. Bublitz, Brian T. Dobrinski, Matthew S. Sanger.
Application Number | 20170015481 15/278718 |
Document ID | / |
Family ID | 53270415 |
Filed Date | 2017-01-19 |
United States Patent
Application |
20170015481 |
Kind Code |
A1 |
Bradford; Judson A. ; et
al. |
January 19, 2017 |
Container Having Dunnage Components Movable In Opposite Directions
and Method of Using Same
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.
Inventors: |
Bradford; Judson A.;
(Holland, MI) ; Bublitz; Timothy A.; (Grand Haven,
MI) ; Dobrinski; Brian T.; (Zeeland, MI) ;
Sanger; Matthew S.; (West Olive, MI) ; Bazany; Donald
J.; (Grand Haven, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bradford Company |
Holland |
MI |
US |
|
|
Family ID: |
53270415 |
Appl. No.: |
15/278718 |
Filed: |
September 28, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14605175 |
Jan 26, 2015 |
9481489 |
|
|
15278718 |
|
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|
|
13956469 |
Aug 1, 2013 |
|
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14605175 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 2519/00815
20130101; B65D 81/022 20130101; B65D 2519/00273 20130101; B65D
2519/00567 20130101; B65D 2519/00338 20130101; B65D 2519/00288
20130101; B65D 88/12 20130101; B65D 2519/00621 20130101; B65D
19/385 20130101; B65D 2519/00502 20130101; B65D 19/18 20130101;
B65D 2519/00796 20130101; B65D 2519/00805 20130101; B65D 2519/0097
20130101; B65D 2519/00174 20130101; B65D 19/06 20130101; B65D
2519/00666 20130101; B65D 2585/6882 20130101; B65D 19/0028
20130101; B65D 25/06 20130101; B65D 2519/00069 20130101; B65D
81/053 20130101; B65D 2519/00034 20130101; B65D 2519/00164
20130101; B65D 25/103 20130101 |
International
Class: |
B65D 81/05 20060101
B65D081/05; B65D 19/38 20060101 B65D019/38; B65D 19/06 20060101
B65D019/06; B65D 81/02 20060101 B65D081/02; B65D 88/12 20060101
B65D088/12 |
Claims
1. A container for holding products therein during shipment, the
container comprising: a metal frame; multiple levels of dunnage for
holding products during storage and shipment; four stationary
corner supports, each stationary corner support being generally
U-shaped in cross-section having a central portion and two side
portions, the central portion and one side portion being secured to
the metal frame; stationary guides supported by each of the
stationary corner supports, each stationary guide extending between
the side portions of the stationary corner support; wherein at
least one level of dunnage comprises multiple movable upper dunnage
components, the guides directing at least one of the dunnage
components to a desired position away from another dunnage
component at the same level to facilitate insertion and removal of
products from another level of dunnage.
2. The container of claim 1 wherein a bottom level of dunnage is
stationary.
3. The container of claim 1 wherein at least one of the dunnage
components is made at least partially of foam.
4. The container of claim 1 wherein at least one of the dunnage
components comprises multiple pieces.
5. The container of claim 1 wherein each of the guides is a
rail.
6. The container of claim 1 wherein at least one of the dunnage
components has a specific geometry for a particular product.
7. A container for holding products therein during shipment, the
container comprising: a metal frame including a base and four
sides; four stationary corner supports, each corner supper having a
central portion and two side portions, the central portion and one
side portion of the corner support being operatively coupled to
adjacent sides of the metal frame; multiple levels of dunnage for
holding products during storage and shipment, at least one level of
dunnage being stationary and at least one level of dunnage being at
least partially movable to facilitate insertion and removal of
products from an interior of the container; and guides supported by
the corner supports, the guides directing at least one dunnage
component of a first level of dunnage to a desired position to
facilitate removal or insertion of products into and out of a
second level of dunnage.
8. The container of claim 7 wherein the first level of dunnage
comprises two dunnage components, each of the dunnage components
having at least one opening through the dunnage component which one
of the guides passes such that the first dunnage component may be
guided to a desired position.
9. The container of claim 7 wherein the second level of dunnage is
stationary.
10. The container of claim 7 wherein at least one of the dunnage
components includes a piece of foam.
11. The container of claim 7 wherein the guides are at least
partially supported by the container.
12. The container of claim 7 wherein each of the dunnage components
has notches for retaining products.
13. The container of claim 7 wherein each of the guides is
supported on one end by a side structure of the container.
14. The container of claim 7 wherein the container has multiple
levels of dunnage.
15. A container for holding products therein during shipment, the
container comprising: a metal frame having two opposed sides;
corner supports secured to the container, each of the corner
supports being generally U-shaped in cross-section having a central
portion and two side portions, the central portion being secured to
one of the front and rear of the container and one side portion
being secured to one of the opposed sides of the container; guides
supported by the corner supports; upper and lower levels of dunnage
for holding products during storage and shipment, the upper level
of dunnage comprising two dunnage components, at least one of the
dunnage components being movable between a first position and a
second position, the dunnage components being closer together when
said at least one of the dunnage components is in the first
position, movement of the dunnage components of the upper level of
dunnage towards each other being limited by the guides, the guides
directing said at least one of the dunnage components of the upper
level of dunnage to facilitate removal or insertion of products
into and out of the lower level of dunnage.
16. The container of claim 15 wherein the lower level of dunnage is
stationary.
17. The container of claim 15 wherein at least one of the dunnage
components is made at least partially of foam.
18. The container of claim 15 wherein at least one of the dunnage
components comprises multiple pieces.
19. The container of claim 15 wherein at least one of the dunnage
components has a specific geometry for a particular product.
20. A container for holding products therein during shipment, the
container comprising: a metal frame including a front, a rear and
at least two opposed sides; four stationary corner supports, each
stationary having a central portion and two side portions, the
central portion being secured to one of the front and rear of the
container and one of the side portions being secured to one of the
opposed sides of the container; multiple levels of dunnage for
holding products during storage and shipment, a bottom level of
dunnage being stationary and an upper level of dunnage comprising a
pair of dunnage components, at least one of the dunnage components
being movable between a first position and a second position, the
dunnage components being further apart when each movable dunnage
component is in the second position for insertion and removal of
parts from the bottom level of dunnage through an opening between
the dunnage components, wherein each movable dunnage component
moves between the side portions of the corner supports; and
stationary guides at vertically spaced levels supported by the
stationary corner supports, each of the stationary guides extending
through openings in the side portions of the stationary corner
supports for directing each movable dunnage component of the upper
level of dunnage to a desired position to facilitate removal or
insertion of products into and out of the bottom level of
dunnage.
21. The container of claim 20 wherein each of the dunnage
components of the upper level of dunnage has at least one opening
through the dunnage component through which one of the stationary
guides passes such that the upper dunnage component may be guided
to a desired position.
22. The container of claim 20 wherein the bottom level of dunnage
is secured to the container.
23. The container of claim 20 wherein at least one of the dunnage
components includes a piece of foam.
24. The container of claim 20 wherein each of the dunnage
components has notches for retaining products.
25. The container of claim 20 wherein the container has two levels
of dunnage.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/605,175 filed Jan. 26, 2015, a
continuation-in-part of U.S. patent application Ser. No. 13/956,469
filed Aug. 1, 2013, which is fully incorporated herein.
FIELD OF THE INVENTION
[0002] 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
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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's body during
loading and/or unloading processes.
[0007] 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.
[0008] Accordingly, there is a need for a container having movable
dunnage in a form other than pouches.
[0009] 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
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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's interior.
[0014] 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.
[0015] 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.
[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. 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.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] 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
[0021] 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.
[0022] FIG. 1 is a perspective view of one embodiment of a reusable
and returnable container;
[0023] FIG. 2 is a perspective view of the container of FIG. 1
showing the dunnage inside the container;
[0024] FIG. 3 is an enlarged perspective view of a portion of the
container shown in FIGS. 1 and 2;
[0025] FIG. 3A is an enlarged perspective view of a portion of
another embodiment of container having upper dunnage components
comprising unitary pieces;
[0026] FIG. 3B is an enlarged perspective view of a portion of
another embodiment of container having different upper dunnage
components;
[0027] FIG. 3C is an enlarged perspective view of a portion of
another embodiment of container having different upper dunnage
components;
[0028] FIG. 3D is an enlarged perspective view of a portion of
another embodiment of container having different upper dunnage
components and different guides;
[0029] FIG. 4 is a partial cross-sectional view of a portion of the
container shown in FIG. 1;
[0030] FIG. 5 is a partial cross-sectional view, like FIG. 4,
showing a different upper dunnage component;
[0031] 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;
[0032] 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;
[0033] 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;
[0034] 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;
[0035] 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;
[0036] 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;
[0037] FIG. 7 is a perspective view of another embodiment of a
reusable and returnable container;
[0038] FIG. 8 is a perspective view of the container of FIG. 7
showing the dunnage inside the container;
[0039] FIG. 9 is a partial cross-sectional view of a portion of the
container shown in FIGS. 7 and 8;
[0040] FIG. 10 is a perspective view of another embodiment of a
reusable and returnable container;
[0041] FIG. 11 is a perspective view of the container of FIG. 10
showing a door or portion of the container being removed;
[0042] FIG. 12 is an enlarged perspective view of a portion of the
container shown in FIG. 10;
[0043] FIG. 13 is a partial cross-sectional view of a portion of
the container shown in FIGS. 10 and 12;
[0044] FIG. 14 is a perspective view of another embodiment of a
reusable and returnable container;
[0045] FIG. 15 is a perspective view of the container of FIG. 14
showing the dunnage inside the container;
[0046] FIG. 16 is an enlarged perspective view of a portion of the
container shown in FIGS. 14 and 15;
[0047] FIG. 17 is a partial cross-sectional view of a portion of
the container shown in FIG. 14;
[0048] FIG. 18 is a perspective view of another embodiment of a
reusable and returnable container;
[0049] FIG. 19 is a perspective view of the container of FIG. 18
turned upside down;
[0050] FIG. 20 is a perspective view of another embodiment of a
reusable and returnable container;
[0051] FIG. 20A is a perspective view of another embodiment of a
reusable and returnable container;
[0052] FIG. 20B is a perspective view of another embodiment of a
reusable and returnable container;
[0053] FIG. 21 is a perspective view of the container of FIG. 20
showing the dunnage and four corner supports which may be used
inside any of the containers;
[0054] FIG. 22 is an enlarged perspective view of a portion of the
interior of the container of FIG. 20 showing a corner inside the
container;
[0055] FIG. 23A is a cross-sectional view of the container shown in
FIG. 20 fully loaded with products showing an upper level of
products being removed;
[0056] FIG. 23B is a cross-sectional view of the container shown in
FIG. 24A showing a second level of products being removed;
[0057] FIG. 23C is a cross-sectional view of the container shown in
FIG. 20 empty showing products being inserted;
[0058] FIG. 23D is a cross-sectional view of the container shown in
FIG. 23B showing additional products being inserted;
[0059] FIG. 24 is an enlarged cross-sectional view of a portion of
the container shown in FIG. 20;
[0060] FIG. 25 is a perspective view of another embodiment of a
reusable and returnable container;
[0061] FIG. 26 is a perspective view of another embodiment of a
reusable and returnable container;
[0062] FIG. 26A is a perspective view of another embodiment of a
reusable and returnable container;
[0063] FIG. 26B is a perspective view of another embodiment of a
reusable and returnable container;
[0064] FIG. 27 is a perspective view of the container of FIG. 26
showing the dunnage inside the container;
[0065] FIG. 28 is an enlarged perspective view of a portion of the
container shown in FIGS. 26 and 27;
[0066] FIG. 29 is a cross-sectional view taken along the line 29-29
of FIG. 28;
[0067] FIG. 30 is a perspective view of another embodiment of a
reusable and returnable container; and
[0068] FIG. 31 is an enlarged perspective view of a portion of an
alternative version of end support.
DETAILED DESCRIPTION OF THE DRAWINGS
[0069] 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.
[0070] The base 14 has an upper surface which functions as a floor
22 of the interior 24 of the container. If desired one or more
pieces of material (not shown) may be located on top of the
container floor 22, such as cushioning materials for example. 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.
[0071] 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.
[0072] 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.
[0073] 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.
[0074] 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.
[0075] As shown in FIG. 4, each of the guides 40 is 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.
[0076] 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.
[0077] 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
automobile fenders.
[0078] 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.
[0079] 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.
[0080] 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.
[0081] FIG. 5 illustrates an alternative upper dunnage component
64a 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 64a has no
generally "U-shaped" liner or stiffener at the bottom thereof.
Instead upper dunnage component 64a has a stiffener 78 in the form
of a block located inside the interior of the body 65 of upper
dunnage component 64a 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.
[0082] 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.
[0083] FIG. 3B illustrates an upper dunnage component 114a 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 114a 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 114a has no liner or stiffener. Each upper
dunnage component 114a is a one-piece unitary body made of foam,
rubber, wood or any other suitable material. These dunnage
components 114a 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 114a of the upper level of dunnage 62 or any of
the levels of dunnage. If desired, the unitary dunnage component
114a shown in FIG. 3B may be incorporated into a dunnage component
having one or more liners or stiffeners in accordance with the
present invention.
[0084] FIG. 3C illustrates a dunnage component 114b which may be
incorporated into any container in place of any of the dunnage
components shown or described herein. Each of the dunnage
components 114b 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, 114a shown in FIGS. 3, 3A, 3B,
respectively, each dunnage component 114b has no opening
therethrough. Instead, each dunnage component 114b 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
114b 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 114b. 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.
[0085] FIG. 3D illustrates another dunnage component 114c which may
be incorporated into any container in place of one of the dunnage
components shown or described herein. Each upper dunnage component
114c has no opening therethrough. Instead, each upper dunnage
component 114c 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 114c 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.
[0086] 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.
[0087] 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'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.
[0088] 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 10a having the shorter guides 40a.
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.
[0089] FIGS. 7, 8 and 9 illustrate an alternative embodiment of
container 10a. Container 10a 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 10a has four guides 40a. Two of the four
guides 40a are front guides, and two are rear guides, each guide
40a being shorter in length than the width "W" of the interior 24
of the container 10a. In this embodiment, one of the rear guides
40a extends between one of the side walls 20 and a support 32
operatively coupled to rear wall 20. The other rear guide 40a
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 40a extends from one of the container side
walls 16 to the nearest support 32. As shown in FIG. 9, each guide
40a 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 40a has opposed
end portions 42a. As shown in FIG. 9, one end portion 42a of each
guide 40a 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 40a. A holder 48, like
the holder 48 shown in FIG. 3, is secured to the guide 40a inside
the washer 46. As best shown in FIG. 9, two holders 48 are secured
to each guide 40a. Each holder 48 is in the form of a triangular
metal wire and has two ends 50 which fit into holes in the guide
40a. The holders 48 function to hold each guide 40a 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 40a from moving further to the left, such that
the right side of the guide 40a 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 40a from moving to
the right, such that the left side of the guide 40a separates from
the side wall 16.
[0090] As shown in FIG. 9, each of the guides 40a is in the form of
a tube having a hollow interior 52a. 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.
[0091] FIGS. 10, 11, 12 and 13 illustrate an alternative embodiment
of container 10b. Container 10b is similar to container 10a and
uses the same dunnage and same four guides 40a. In this embodiment,
two of the four supports 32b are operatively coupled to rear wall
20 below a section 88 which may be removable or a drop down door.
Although not shown, the other two of the four supports 32b are
operatively coupled to front wall 18 below another section 88 which
may be removable or a drop down door. 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 and function as a door.
[0092] As shown in FIG. 12, two of the four supports or brackets
32b are each operatively coupled with fasteners 92 to container
rear wall 20 below the section 88 so as to not interfere with the
removal or lowering of the wall section 88 of rear wall 20. The
other two supports 32b are operatively coupled to the front
container wall 18 below the section 88 so as to not interfere with
the removal or lowering of the wall section 88 of front wall 18. As
shown in FIG. 12, each of the supports 32b 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 32b 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 40a, as best illustrated in
FIG. 12. As shown in FIGS. 12 and 13, the other end of each guide
40a 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.
[0093] FIGS. 14-17 illustrate an alternative embodiment of
container 10c. Container 10c is similar to container 10a and uses
the same dunnage and same four guides 40a. However, in container
10c, the supports 32c are not eye bolts. As best shown in FIG. 15,
two of the four supports 32c are secured to rear wall 20, and the
other two of the four supports 32c are secured to front wall 18 in
any conventional manner.
[0094] As best shown in FIGS. 16 and 17, each of the supports 32c
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 40a passes through an opening in one wall of the bracket 108
(the innermost wall) and through the body 112 of the support 32c.
Thus, each support 32c is sized to receive and retain one end of
one of the guides 40a, as best illustrated in FIG. 17. As shown in
FIGS. 16 and 17, the other end of each guide 40a 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 40a. 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 40a. The holder 48 at one end of each guide 40a
functions to hold each guide 40a in place. The holder 48 helps
prevent the guide 40a from moving to the left, as shown in FIG. 16
and discussed herein. The other end of guide 40a passes through one
of the sides of bracket 108 and through the body 112 of the support
32c, abutting the opposed side of bracket 108.
[0095] FIGS. 18-19 illustrate an alternative embodiment of
container 10d. Container 10d is similar to container 10c shown in
FIGS. 14-17 in that container 10d uses the same dunnage, guides 40a
and supports 32c as container 10c. However, in container 10d, the
side structures are not solid walls. As best shown in FIG. 18,
container 10d 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 10d 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).
[0096] 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 32c are
welded or otherwise secured to the intermediate rear braces 136
(one support 32c per intermediate rear brace 136). The other two
supports 32c are welded or otherwise secured to the vertical
members 164 of the front gates 160 described below (one support 32c
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.
[0097] 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 40a 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.
[0098] 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.
[0099] A floor 156 rests on top of the bottom of the metal outer
frame 120. If desired one or more pieces of material (not shown)
may be located on top of the container floor 156, such as
cushioning materials for example. 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.
[0100] The metal frame 120 further comprises two front gates 160,
one on each side of the container 10d. 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.
[0101] Although the outer metal rack or frame 120 is shown only in
FIGS. 18 and 19 with guides 40a and supports 32c, 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.
[0102] FIGS. 20 and 21-24 illustrate another embodiment of
container 10e. Container 10e, as shown, comprises a body 170 having
a base 172, a front wall 173, a rear wall 175 and two sides or side
structures 174, all extending upwardly from the base 172. As shown
in FIG. 20, each of the sides or side structures 174 may have a
movable door 171 to facilitate insertion or removal of products
260. Two or more of the walls or sides may or may not be hingedly
secured to the base 172. Each of the doors 171 may be lowered in
any known manner. Although one style and size of door is
illustrated, any known door of any size may be used in accordance
with any of the containers shown or described herein.
[0103] FIG. 20A illustrates another embodiment of container 10ee
similar to container 10e except the front and rear sides or walls
173, 175 of the container have doors 171, as opposed to the side
walls 174 having doors, as shown in the embodiment of FIG. 20.
[0104] FIG. 20B illustrates another embodiment of container 10eee
similar to container 10ee except the container has no movable doors
171. Instead of doors, container 10eee has two cut-outs or openings
177, one in the front wall 173 and one in the rear wall 175.
Although not shown, the side walls 174 may have cut-outs or
openings.
[0105] As shown in FIG. 21, the base 172 of container 10e has an
upper surface 202 which may function as a floor of the interior 204
of the container 10e. If desired, one or more pieces of material
(not shown) may be located on top of the container floor 202, such
as cushioning materials, for example. As shown in FIG. 20, each of
the container sides 174 has an inner surface 206. As shown in FIG.
20, the floor 202 and interior surfaces 206 of sides 174 define the
interior 204 of container 10e. The linear distance between the
interior surfaces 206 of opposed sides 174 defines a width "W1" of
the interior 204 of container 10e. The linear distance between the
interior surfaces 206, of the other two opposed sides 174, defines
a length "L1" of the interior 204 of container 10e. As shown in
FIGS. 20A and 20B, the same is true of container 10ee of FIG. 20A
and container 10eee of FIG. 20B.
[0106] As best shown in FIG. 21, the interior of container 10e (and
containers 10ee and 10eee) comprises four stationary corner
supports 176. As shown in FIG. 22, each corner support 176 is
operatively coupled to two adjacent walls or sides of the container
10e with fasteners 179 (only two fasteners 179 being shown). As
best seen in FIG. 22, each fastener 179 extends through an opening
182 in each corner support 176. Each of the corner supports 176 is
generally U-shaped in cross-section, having a central portion 178
and two side portions 180. Each side portion 180 is oriented
generally orthogonal to the central portion 178. Each corner
support 176 is preferably made of metal, but may be made of any
suitable material. Each of the corner supports 176 does not move
during the loading or unloading processes. Although a certain
number of openings 182 are illustrated in the central portion 178
and outer side portion 180 of each corner support 176, the drawings
are not intended to be limiting. Any number of openings of any
desired size may be incorporated into each corner support 176 to
help secure the corner support 176 to the walls or sides (outer
shell) of the container 10e (or container 10ee or container 10eee)
with fasteners 179. Alternatively, the fasteners may extend through
the central portion 178 and outer side portion 180 of each corner
support 176, thereby eliminating the need for openings in the
corner supports.
[0107] As best shown in FIG. 22, a rectangular cushion pad 184 may
be secured with fasteners 186 to an inner side portion 180 of each
of the corner supports 176. As shown in detail in FIG. 24, each
cushion pad 184 has a plurality of vertically spaced bores 185
therethrough. Each bore 185 is sized to allow a guide 188 to pass
through the cushion pad 184 at the proper location. Each cushion
pad 184 may be made of foam, fiber, rubber or any other cushioning
material to prevent damage to products or parts being shipped.
[0108] As shown in FIGS. 20-24, container 10e (or any other
container shown or described herein, including containers 10ee and
10eee) further comprises multiple guides 188 at each level. In the
illustrated embodiment, four parallel guides 188 are located at
each level; two at the front and two at the rear of the container
10e. As best shown in FIG. 22, each of the guides 188 extends
through aligned openings 190 through the side portions 180 of each
corner support 176. As best shown in FIGS. 20 and 22, each of the
guides 188 has a length greater than the width "W2" of the interior
of the corner support 176. Therefore, as best shown in FIG. 22,
each guide 188 has an enlarged head or end portion 192 which is too
big to pass through one of the openings 190. As shown in FIG. 22,
the head 192 of each guide 188 is located between one of the
container sides 174 and an outer side portion 180 of a corner
support 176, thereby eliminating the need to secure the guide 188
to the container. As best shown in FIG. 22, the opposite end of the
guide 188 extends through one of the holes 190 in the other side
portion 180 of the corner support 176. Although no holder, such as
a cotter pin or triangular wire, etc. is illustrated extending
through the guide 188, such a holder may be used to prevent
movement of a guide 188.
[0109] As shown in FIG. 24, each of the guides 188 is in the form
of a tube having a hollow interior 198. 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. The guide need not have a
circular cross-section; it may be any desired shape in
cross-section as long as the openings in the side portions 180 of
the corner supports 176 match.
[0110] As shown in FIGS. 21 and 23A-23D, container 10e further
comprises a bottom level of dunnage 200 supported by the floor 202
of the container 10e. This bottom level of dunnage 200 may be
fixedly secured directly or indirectly to the floor 202 of the
container 10e. In the illustrated embodiment, this bottom level of
dunnage 200 comprises a pair of stationary dunnage components 208
spaced from one another. As best shown in FIG. 21, each stationary
dunnage component 208 has a plurality of spaced notches 210 and a
plurality of spaced projections 212. The notches 210 are for
receiving and retaining products 260, as shown in FIG. 20, one of
the products 260 extending between a pair of corresponding notches
210 in the stationary dunnage components 208. Although one specific
shape of notch 210 is illustrated in the drawings, this document is
not intended to limit in any way the size, shape or configuration
of notches 210 in any of the dunnage components 208 of the lower
level of dunnage 200. If desired, more than two dunnage components
may comprise the lowest or bottom level of dunnage 200.
Alternatively, a single dunnage component or member may comprise
the lowest level of dunnage. In some applications, the bottom level
of dunnage may be movable and include guides like all the other
levels of dunnage. Although the stationary dunnage components 208
are illustrated in FIG. 21 being spaced from each other the same
distance as the movable dunnage components when the movable dunnage
components are moved inwardly, the stationary dunnage components
208 may be closer together or further apart than illustrated in
FIG. 21.
[0111] Although one specific shape of product 260 is illustrated,
this document is not intended to limit in any way the size, shape
or configuration of product 260 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 automobile
fenders.
[0112] As shown in FIGS. 20-24, container 10e further comprises
multiple levels of movable dunnage 214 above the bottom dunnage
level 200. Although FIG. 21 illustrates four levels of movable
dunnage 214, any number of levels of movable dunnage may be inside
any of the containers shown or described herein. As best shown in
FIG. 21, each movable level of dunnage 214 comprises a pair of
movable dunnage components 216 spaced from one another. Each
movable dunnage component 216 of each level of movable dunnage 214
is movable inside the interior 204 of the container 10e (or other
containers illustrated or described herein, such as containers 10ee
and 10eee) between open and closed positions. FIGS. 21 and 22
illustrate each movable dunnage component 216 in a closed position.
As best illustrated in FIG. 22, each of the movable dunnage
components 216 moves between one of the side portions 180 of a
corner support 176 (attached to one of the container sides 174) and
one of the cushion pads 184. When the movable dunnage component 216
is adjacent one of the side portions 180 of a corner support 176,
as shown in FIG. 23C, the movable dunnage component 216 is
considered in its open position. When the movable dunnage component
216 is adjacent one of the cushion pads 184 attached to the other
side portion 180 of a corner support 176, as shown in FIG. 23A, the
movable dunnage component 216 is considered in its closed
position.
[0113] Each movable dunnage component 216 is shown being identical
to one of the stationary dunnage components 208 of the bottom
dunnage level 200, but with additional components described herein.
However, the movable dunnage components 216 may differ in shape
and/or configuration than the bottom dunnage components 208. Like
the bottom dunnage components 208, each movable dunnage component
216 has a plurality of spaced notches 210 and a plurality of spaced
projections 212 for receiving and retaining products 260 in the
notches 210, as shown in the drawings.
[0114] Although one specific shape of notch 210 and projection 212
are illustrated in the drawings, this document is not intended to
limit in any way the size, shape or configuration of notches and/or
projections in any of the dunnage components of any of the dunnage
levels. For example, the dunnage components may be made partially
or entirely of wire, may comprise pouches or may have openings
therein to receive and retain portions of products.
[0115] As shown in FIG. 24, each of the movable dunnage components
216 of a movable level of dunnage 214 has a main portion or body
218 having a bore 220 therethrough. The body 218 is commonly made
of foam, but may be made of other materials. As best shown in FIG.
24, a sleeve 222 may extend through bore 220 in the dunnage body
218 of the movable dunnage component 216. The sleeve 222 moves with
the dunnage component 216. Each hollow sleeve 222 is sized to allow
one of the guides 188 to extend through the sleeve 222. If desired,
the sleeves 222 may be omitted, in which case one of the guides 188
would pass directly through a bore in the dunnage body 218.
[0116] As shown in FIGS. 22 and 24, one or more of the movable
dunnage components 216 of a movable level of dunnage 214 may have a
stiffener 224 and a cushion 226. The stiffener 224 is located
between the cushion 226 and body 218 of dunnage component 216. As
shown in FIG. 24, a glue layer 230 may be located between the lower
surface of the body 218 and the stiffener 224 to secure them
together. As best shown in FIG. 24, the stiffener 224 and cushion
226 of the movable dunnage component 216 are each generally
"U-shaped"and fit around a lower portion of the body 218 of movable
dunnage component 216. The stiffener 224 may be made of foam, metal
and/or plastic and provides rigidity in two directions to the
dunnage component 216. The cushion 226 may be partially or entirely
made of foam and/or plastic. Each cushion 226 prevents products 260
from damage, such as being scratched while being loaded and/or
unloaded. As shown in FIGS. 22 and 24, threaded fasteners 228, such
as drywall screws, may secure the body 218 of movable dunnage
component 216, the stiffener 224 and cushion 226 together. Other
known means, including additional adhesive, may be used to secure
the body 218 of movable dunnage component 216, the stiffener 224
and cushion 226 together with or without the fasteners 228. If
desired, the stiffener 224 and/or cushion 226 of the movable
dunnage component 216 may be omitted.
[0117] FIGS. 23A-23B illustrate a method of unloading products 260
from a fully loaded container 10e (or any other container
illustrated or described herein). The method comprises the first
step of pulling products 260 extending between the two dunnage
components 216 of the top level or layer of dunnage 214 out of the
upper level of dunnage and out of the container 10e in the
direction of arrow 232. As shown in FIG. 23B, the two movable
dunnage components 216 of the top level or layer of dunnage 214 are
then moved outwardly away from each other in the direction of
arrows 234. More specifically, an operator moves them from a first
or closed position shown in FIG. 23A to a second or open position
illustrated in FIG. 23B. As shown in FIG. 23B, when the two dunnage
components 216 of the top level of dunnage 214 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. 23A.
When one or both of the dunnage components 216 are moved away from
each other, access to a lower level of dunnage is improved and
helps prevent undesirable damage to the products being removed from
the interior of the container. The increased spacing between the
movable dunnage components also makes unloading lower products
easier from an ergonomic standpoint, thereby improving worker
efficiency and productivity.
[0118] As shown in FIG. 23B, the next step comprises removing a
second level of products 260 extending between the movable dunnage
components 216 of the next lowest level of movable dunnage 214, the
two dunnage components 216 of the top level of dunnage 214
remaining in their second or open position. With the dunnage
components 216 of the upper level of dunnage 214 being in their
second or open position, products 260 in the next level of movable
dunnage 214 may be more easily removed from the container in the
direction of arrow 236 without the dunnage components 216 of the
upper level of dunnage 214 being in the way or obstructing the
removal of the lower level of products though the opening. This
process is repeated one level at a time moving downwardly until
products 260 supported by the lowest or bottom level of stationary
dunnage 200 are removed from inside the container 10e.
Alternatively, only one side of movable dunnage components 216 may
be moved and the other side remains stationary during either the
loading or unloading process.
[0119] FIGS. 23C-23D illustrate a method of loading products 260
into an empty container 10e. As shown in FIG. 23C, products 260 are
loaded into the container's interior 204 by an operator in the
direction shown by arrow 238 between the movable dunnage components
216 of multiple levels of movable dunnage 214 (which are in their
open position). Thus, products 260 are loaded into the lowest or
bottom level of dunnage 200 and, more specifically, loaded such
that each product 260 extends between the stationary dunnage
components 208 of the lowest or bottom level of dunnage 200. As
shown in FIG. 23D, once the lowest level of dunnage 200 contains
the desired number of products 260, the two movable dunnage
components 216 of the next highest level or layer of dunnage 214
are then moved inwardly towards each other in the direction of
arrows 240 to a closed position. More specifically, an operator
moves them from a second or open position shown in FIG. 23C to a
first or closed position illustrated in FIG. 23D. The distance
movable dunnage components 216 travel inwardly is limited by the
size and location of corner supports 176 and cushion pads 184. Each
of the movable dunnage components 216 of the upper level of dunnage
214 does not travel between the cushion pads 184. In other words,
each of the movable dunnage components 216 of a movable level of
dunnage 214 does not travel inside the cushion pad 184 closest to
it. This step of loading products 260 into levels one at a time
(moving upwardly) by inserting the products 260 in the direction of
arrow 242 continues until the container 10e is full.
[0120] FIG. 25 illustrates an alternative embodiment of container
10f. Container 10f is similar to container 10e shown in FIGS. 20-24
in that container 10f uses the same dunnage and corner supports 176
as container 10e. However, in container 10f, the container side
structures are not solid walls. The outside or shell of the
container is considered a rack structure, typically made of metal.
Although the rack 244 shown in FIG. 25 is one configuration, the
drawings are not intended to limit the style of rack used in
accordance with the invention. For example, the rack or frame 120
shown in FIGS. 18 and 19, or any similar metal rack, may be used in
place of the rack or frame 244 shown in FIG. 25.
[0121] Although one configuration of outer metal rack or frame 244
of container 10f is shown in FIG. 25, other configurations of outer
metal racks may be used in accordance with the inventions described
herein. Any of the dunnage systems shown or described herein may be
used in any container having an outer metal rack or frame,
including but not limited to, the outer metal rack or frame 244
shown in FIG. 25.
[0122] As shown in FIG. 25, container 10f further comprises
multiple guides 188 at each level. As best shown in FIG. 25, each
of the guides 188 extends through aligned openings 190 through the
side portions 180 of each corner support 176. As best shown in FIG.
25, each of the guides 188 has a length greater than the width of
the interior of the corner support 176. As shown in FIG. 25, each
guide 188 has one head 192 (only one side being shown in FIG. 25)
located outside the outer wall 180 of one of the corner supports
176. As best shown in FIG. 25, a holder 196 (shown in the form of a
cotter pin just inside the inner side portion 180 of each corner
support 176) may extend through an opening in the guide 188 to
prevent lateral movement of the guide 188. One holder 196 and the
head 192 function to hold each tubular guide 188 in place. Although
not shown a pair of holders 196, acting in concert, may function to
prevent a guide 188 lacking a head 192 from separating from the
container. Although one configuration of holder in the form of a
cotter pin is shown and described, other types of holders, such as
triangular wires or pieces of other materials configured in other
shapes, may be used as holders to prevent movement of the guides
188, which may be any desired shape in cross-section.
[0123] Each of the guides 188, like each of the guides 40 shown in
FIG. 4, may be in the form of a tube having a hollow interior.
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.
[0124] FIGS. 26-29 illustrate another embodiment of container 10g.
Container 10g, as shown, comprises the same body 170 shown in FIG.
20 and described above. As best shown in FIG. 27, the interior 248
of container 10g (and containers 10gg and 10ggg) comprises four
stationary end supports 246, in place of four corner supports 176
shown in the containers of FIGS. 20-25. Furthermore the container
10g (and container 10gg and container 10ggg) lack guides 188, 189
shown in the containers of FIGS. 20-25.
[0125] FIG. 26A illustrates another embodiment of container 10gg
identical to container 10g except the front and rear sides or walls
173, 175 of the container have doors 171, as opposed to the side
walls 174.
[0126] FIG. 26B illustrates another embodiment of container 10ggg
identical to container 10gg except the container has no doors 171.
Instead of doors, container 10ggg has two cut-outs or openings 177,
one in the front wall 173 and one in the rear wall 175. Although
not shown, the side walls 174 may have cut-outs or openings.
[0127] As best shown in FIG. 27, the interior of container 10g (and
containers 10gg and 10ggg) comprises four stationary end supports
246. As shown in FIG. 27, two end supports 246 are operatively
coupled or secured to each of the front and rear walls 173, 175 of
the container with fasteners 179 (only one fastener 179 being shown
in FIG. 28). Alternatively, the end supports may be secured to the
side walls, orienting the dunnage ninety degrees from the
orientation shown in FIGS. 26 and 27. As best seen in FIG. 28, each
fastener 179 extends through an opening 250 in each end support 246
and into one of the container sides or walls. As best seen in FIG.
28, each of the end supports 246 may be a generally rectangular and
generally planar unitary member, having a top edge 252, a bottom
edge (not shown) and two side edges 254. Alternatively, as shown in
FIG. 31, each end support may be made of multiple members. Each end
support 246 is preferably made of metal, but may be made of any
suitable material. Each of the end supports 246 does not move
during the loading or unloading processes.
[0128] Although a certain number of openings 250 are illustrated in
each end support 246, the drawings are not intended to be limiting.
Any number of openings of any desired size may be incorporated into
each end support 246 to help secure the end support 246 to one of
the walls or sides (outer shell) of the container 10g (or container
10gg or container 10ggg) with fasteners 179. Alternatively, the
fasteners may extend through each end support 246, thereby
eliminating the need for openings in the end support 246.
[0129] As best seen in FIG. 28, each end support 246 has a series
of vertically spaced turnouts 256, one at each level or layer. Each
turnout 256 comprises a piece of material or tab 258 extending
outwardly from the end support 246, the tab 258 having a linear
slot 262 therein. In the embodiment shown, the material of the end
support 246 is cut along a generally U-shaped pattern and then bent
to a position in which it is generally perpendicular to the
remainder of the end support 246, thereby leaving an opening 264 in
the end support 246. Alternatively, extra material for the slotted
tab may be welded in place without removing material from the
remainder of the end support 246.
[0130] As shown in FIGS. 26-29, container 10g further comprises
multiple levels of movable dunnage 214' above the bottom dunnage
level 200'. Each level of dunnage 214' is movable inside the
interior 248 of the container 10g or other containers illustrated
or described herein, such as containers 10gg and 10ggg. As best
shown in FIG. 27, each movable level of dunnage 214' comprises a
pair of movable dunnage components 216' spaced from one another.
Each movable dunnage component 216' is shown being identical to one
of the stationary dunnage components 208 of the bottom dunnage
level 200', but with additional components described herein.
However, the movable dunnage components 216' may differ in shape
and/or configuration than the bottom dunnage components 208. Like
the bottom dunnage components 208, each movable dunnage component
216' has a plurality of spaced notches 210 and a plurality of
spaced projections 212 for receiving and retaining products 260 in
the notches 210, as shown in FIG. 23A. Although one specific shape
of notch 210 and projection 212 are illustrated in the drawings,
this document is not intended to limit in any way the size, shape
or configuration of notches and/or projections in any of the
dunnage components of any of the dunnage levels.
[0131] As shown in FIG. 29, each of the movable dunnage components
216' of a movable level of dunnage 214' has a main portion or body
218'. The body 218' is commonly made of foam, but may be made of
other materials.
[0132] As shown in FIGS. 28 and 29, one or more of the movable
dunnage components 216' of a movable level of dunnage 214' may have
a stiffener 224' and a cushion 226'. The stiffener 224' is located
between the cushion 226' and body 218' of dunnage component 216'.
As shown in FIG. 29, a glue layer 230 may be located between the
lower surface of the body 218' and the stiffener 224' to secure
them together. As best shown in FIG. 29, the stiffener 224' and
cushion 226' of the movable dunnage component 216' are each
generally "U-shaped" and fit around a lower portion of the body
218' of movable dunnage component 216'. The stiffener 224' may be
made of foam, metal and/or plastic and provides rigidity in two
directions to the dunnage component 216'. The cushion 226' may be
partially or entirely made of foam and/or plastic. Each cushion
226' prevents products 260' from damage, such as being scratched
while being loaded and/or unloaded. As shown in FIGS. 27 and 28,
threaded fasteners 228, such as drywall screws, may secure the body
218' of movable dunnage component 216', the stiffener 224' and
cushion 226' together. Other known means, including additional
adhesive, may be used to secure the body 218' of movable dunnage
component 216', the stiffener 224' and cushion 226' together. If
desired, the stiffener 224' of the movable dunnage component 216'
may be omitted.
[0133] As best shown in FIG. 29, the cushion 226' of the movable
dunnage component 216' has two pegs 266, one at each end, extending
downwardly from a bottom portion thereof. Each peg 266 is adapted
to move inside one of the slots 262 of one of the tabs 258 of one
of the end supports 246. As best illustrated in FIG. 28, each of
the movable dunnage components 216' moves between a closed position
in which the pegs 288 of the movable dunnage component 216' (part
of the cushion 226') are located at the innermost ends of the slots
262 of corresponding tabs 258 along one side of the container and
an open position in which the pegs 266 of the movable dunnage
component 216' (part of the cushion 226') are located at the
outermost ends of the slots 262 of corresponding tabs 258 on the
opposed side of the container.
[0134] FIG. 30 illustrates an alternative embodiment of container
10h. Container 10h is similar to container 10g shown in FIGS. 26-29
in that container 10h uses the same dunnage and end supports as
container 10g. However, in container 10h, the container side
structures are not walls, and the end supports may be welded to an
outside shell of the container 10h. The outside shell of the
container is considered a rack structure, typically made of metal.
Although the rack 244' shown in FIG. 30 is one configuration, the
drawings are not intended to limit the style of rack used in
accordance with the invention. For example, the rack or frame 120
shown in FIG. 18 or any similar metal rack may be used in place of
the rack or frame 244' shown in FIG. 30.
[0135] FIG. 31 illustrates an alternative configuration of end
support 248' shown partially disassembled. End support 248' is made
of multiple pieces 268, 269, each piece 268, 269 having multiple
openings 270 adapted to receive fasteners to secure the end support
248' to one of the side structures or walls of any of the
containers shown or described herein. Although each piece 268 is
illustrated having two openings 270, each piece 268, 269 may have
any number of openings of any desired size or configuration.
[0136] Each piece 268 comprises a generally planar portion 272
through which the openings 270 extend and a slotted tab 274
extending outwardly from the top of the generally planar portion
272. Each tab 274 has a linear slot 276 therein in which the pegs
266 ride. The generally planar portion 272 has two spaced,
generally V-shaped projections 278 extending outwardly from a lower
edge 280 of each end support piece 268. Each projection 278 is
adapted to fit into a generally V-shaped receptacle 282 formed in
the generally planar portion 272 of another end support piece 268,
to prevent or inhibit movement of one end support piece 268
relative to another. Each projection and receptacle may be shapes
other than those illustrated to inhibit movement between end
support pieces.
[0137] Although not shown, the material of the generally planar
portion 272 of end support piece 268 may be cut along a generally
U-shaped pattern and then bent to a position in which it is
generally perpendicular to the remainder of the end support piece
268, thereby leaving an opening in the end support piece 268, as
shown in FIGS. 27 and 28 and described herein.
[0138] As shown in FIG. 31, each end support piece 269 comprises a
generally planar portion 284 through which the openings 270 extend,
and two spaced V-shaped projections 286 extending outwardly from a
lower edge 288 of each end support piece 269. Each projection 286
is adapted to fit into a receptacle 282 formed in the generally
planar portion 272 of an end support piece 268, to prevent or
inhibit movement of support pieces 268, 269 relative to each other.
Although FIG. 31 illustrates one end support piece 269 above four
end support pieces 268, other combinations are possible. For
example, end support piece 269 may have openings 282 like those
shown in end support pieces 268, in which case any combination of
end support pieces 268, 269 may be joined together.
[0139] 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.
* * * * *