Note: Descriptions are shown in the official language in which they were submitted.
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CONTAINER HAVING METAL OUTER FRAME FOR
SUPPORTING L-SHAPED TRACKS
Cross Reference to Related Applications
[0001] This application is a continuation-in-part of U.S. Patent Application
Serial No.
13/616,635 filed September 14, 2012, which is fully incorporated by reference
herein.
Field of the Invention
[0002] The present invention relates to containers for use in shipping and,
more
particularly, to containers with movable members for supporting product.
Background of the Invention
[0003] A large number of different container structures are utilized by
manufacturers to
ship a variety of different products to end users, which may be, for example,
assembly
plants. In the automobile industry, for example, an assembly plant assembling
a
particular automobile might utilize a number of different parts from different
manufacturers. These manufacturers ship their respective parts to the assembly
plant
in container structures where the parts are then removed from dunnage or
support
members inside the container structure and assembled into a finished
automobile.
[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
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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 distal or rear part of the container. The size and/or weight of the parts or
work pieces
may cause stress or strain on the line worker and, more particularly, on the
back of the
worker when inserting or removing parts from such a container. Such
ergonomically
unfriendly movements may cause physical trauma, pain and other injuries that
may lead
to lost production time.
[0006] In some situations, in order to alleviate such stress and/or strain on
his or her
body, the line worker may move to the rear or opposite end of the container to
remove
parts from inside the container. This requires space around the container
which may
not be available, depending on the physical layout of the plant or facility.
The length
(front to back) of certain containers may be limited because the container
manufacturer
needs to eliminate the need for a line worker to walk around the container to
remove
product from inside the container. Such containers having a reduced length
reduce the
number of parts or products which may be shipped and/or stored in the
container. The
more containers needed to ship a predetermined number of parts, the greater
the cost
to the shipper.
[0007] In other containers, a line worker or employee must lean forward and
bend
down into the container to insert or remove a part or work piece from a lower
portion of
the container. This movement by the line worker is ergonomically unfriendly
because
the line worker must lean forward and bend down and lift a part or workpiece
up and
over a wall into the container to remove the part or work piece from inside
the container.
Similarly, when a part or workpiece must be inserted into a container, the
line worker
may have to lean forward and insert the part, which may be heavy, into its
proper
location inside the container, again experiencing ergonomically unfriendly
movements.
Such movements may be necessary with many top loading containers and/or
containers
having multiple layers or levels of parts.
[0008] Depending upon the number of times the line worker repeats this
unnatural
motion into the interior of the container, strain in the back, legs and arms
may result.
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The size and/or weight of the parts or work pieces may increase the strain on
the line
worker. Thus, simply removing multiple parts during a work day may cause
physical
trauma, pain and other injuries that may lead to lost production time.
[0009] Accordingly, there is a need for a container which prevents employees
from
walking around the container to insert or remove product from inside the
container.
[0010] There is further a need for a container which prevents employees from
having
to perform difficult or straining repetitive reaching motions.
[0011]
There is further a need for a container which brings product into an
ergonomically friendly area or zone for insertion or removal of the product.
Summary of the Invention
[0012] The present invention provides a container for holding product therein
during
shipment that comprises a metal frame having a bottom and two sides. In one
embodiment, a generally L-shaped stationary track is secured to each side of
the metal
frame. Each of the generally L-shaped stationary tracks has a substantially
horizontally
oriented portion and a substantially vertically oriented portion when the
container is
resting on the floor. The substantially horizontally oriented portion of each
track is
located proximate the open top of the container, and the substantially
vertically oriented
portion is located proximate the front of the container where a door may be
located.
[0013] The container further comprises a plurality of movable slider
assemblies or
support member assemblies that are supported by the stationary tracks. For
purposes
of the present invention, the terms "slider assembly" and "support member
assembly"
may be used interchangeably; either may include multiple components secured
together. For example, a "slider assembly" may comprise in combination a
tubular
support and a pair of end members which move or slide inside stationary
tracks, both in
a horizontal direction and vertical direction.
[0014] Similarly, for purposes of the present invention, the term "track" may
be a
unitary member or multiple components secured together. The present invention
is not
intended to be limited to the tracks like those illustrated and described
herein. For
example, a "track" may comprise a groove in one or more walls of a container.
The term
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"track" is intended to include any number of stationary objects along which
support
members or support member assemblies as defined and/or illustrated herein may
slide
or move during the loading or unloading of products from dunnage inside the
container.
Tracks, like those disclosed in U.S. Patent Application Serial No. 13/225,835,
published
as U.S. Patent Publication No. US2013/0057135, fully incorporated by reference
herein,
may be used to support the support member assemblies and associated dunnage
for
movement inside the container.
[0015] According to another aspect of the present invention, the container has
a metal
frame having a base and at least two sides. Tracks are secured to opposed
sides of the
metal frame, each of the tracks having at least one generally horizontally
oriented
portion and at least one generally vertically oriented portion which remain
fixed during
the loading and unloading of products. Each generally vertically oriented
portion may
extend downwardly from an end of the generally horizontally oriented portion
of each
track. Each of the stationary generally "L"-shaped tracks may have a curved or
arcuate
corner having a radius. Each of the tracks may be made of any number of pieces
of
material or be a unitary piece.
[0016] A plurality of support member assemblies is located generally inside
the
container. Each of the support member assemblies may comprise a pair of
sliders or
end members movable along the stationary tracks and a support extending
between the
sliders. Dunnage is supported by the support member assemblies. The dunnage
may
be pouches or any other known dunnage. The dunnage may be secured to the
support
member assemblies in any known manner, including those disclosed in U.S.
Patent
Application Serial No. 13/225,835.
[0017] The container may also include at least one space limiter attached to
the
dunnage to limit the distance adjacent support member assemblies may be moved
or
separated from each other. Each space limiter may be a fabric strap or like
component
that can flex when the distance between the support member assemblies is
minimized
and yet only stretch a predetermined distance to allow the support member
assemblies
to move a predetermined distance apart from each other. Space limiters or
straps may
be located on opposite sides of the container so two straps connect front and
rear walls
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of a pouch or adjacent pouches. The straps may be made of the same material as
the
dunnage, or may be any other suitable material.
[0018] According to another aspect of the invention, the container comprises a
metal
frame having a base and at least two sides extending upwardly from the base.
Tracks
may be secured to opposed sides of the frame, each track comprising a
generally
horizontally oriented portion and at least one generally vertically oriented
portion. Each
generally vertically oriented portion may extend downwardly from an end of the
generally
horizontally oriented portion of each track.
[0019] In some embodiments, the container has a movable door on one side of
the
container which may be lowered for ergonomic reasons. An operator may find
loading
and/or unloading parts from the dunnage in the container to be easier and less
stressful
on his/her body when the door is in a lowered position. Alternative containers
may have
two doors on opposite sides of the container. Each of the doors, regardless of
whether
the container has one or two doors, may comprise multiple panels, at least one
of which
may be movable.
[0020] In the situation in which each side of the container has a track having
two
generally vertically oriented portions extending downwardly from opposite ends
of a
generally horizontal portion of the track, the container could have two doors.
In such a
container, each of the stationary generally "U-shaped" tracks may have curved
or
arcuate corners, each corner having a radius. The container further comprises
support
member assemblies supported by the tracks and extending therebetween. Each of
the
support member assemblies comprises a pair of end members engaged with and
movable along the tracks and a support extending between the end members, the
support surrounding a portion of each of the end members. The container
further
comprises dunnage supported by the support member assemblies.
[0021] According to another aspect of the invention, the container comprises a
metal
body. Stationary tracks, supported by the metal body of the container, may
comprise at
least one generally horizontally oriented portion and at least one generally
vertically
oriented portion. The container may further comprise movable support member
assemblies supported by the stationary tracks and extending therebetween. Each
of the
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support member assemblies may comprise a pair of sliders or end members
engaged
with and slidable along the tracks and a tubular support extending between the
sliders,
the tubular support surrounding a portion of each of the sliders. The elongate
tubular
support may be secured to sliders at the ends thereof. The tubular support may
be
made of metal, such as aluminum; but may be made of any other suitable
material, such
as plastic. The container further comprises dunnage supported by the support
member
assemblies.
[0022] According to another aspect of the invention, the container comprises
at least
one slidable or movable door. Each door may comprise one or more panels or
segments. In some embodiments, the dunnage may be attached to the door or
doors.
[0023] The container may be adapted so that an operator located at the front
of the
container may pull product to be emptied from the rear of the container
forwardly to a
more ergonomically friendly position after products suspended from dunnage at
the front
of the container have been unloaded or removed. Thus, a person unloading the
container from the front or proximal location of the container will not have
to stretch or
reach to the back of the container to unload remaining product.
[0024] Similarly, a person loading the container from the front of the
container need not
stretch or reach to the back of the container to insert or load product into
the container.
The loader of the container may push the support member assemblies and
associated
dunnage loaded with product rearwardly and load additional product in a more
ergonomically friendly position or manner. For example, after product is
loaded into
dunnage suspended by adjacent support member assemblies, these support member
assemblies and associated dunnage are pushed rearwardly to enable the loader
to load
additional product. Thus, the container allows product to be more efficiently
and safely
removed from the container or inserted therein without unnecessary stress or
strain on
the operator. [0025] The sliders or end members may be made of plastic or any
other
desired material. The sides of the container have horizontally oriented track
portions in
which the sliders move to move dunnage supported by the support member
assemblies
closer to the user for loading or unloading product. Each slider may have at
least one
head located inside the interior of the track so the slider remains engaged
with the track.
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The slider may have another head outside the track for preventing the dunnage
material from entering the interior of the track.
[0026] The horizontally oriented tracks may have openings therein and
removable
caps for covering and/or closing the openings. If one or more of the supports
or support
member assemblies needs to be removed or inserted, a person may remove and/or
insert one or more support member assemblies via the openings in opposed
tracks.
[0027] In some embodiments having a single door, the generally vertically
oriented
track portions may be located at the front of the container only proximate the
door. In
such embodiments, the container has two generally vertically oriented track
portions,
one on each side of the container. Alternatively, in some embodiments, the
containers
may have two doors and generally vertically oriented track portions proximate
each
door. In such embodiments, the container has four generally vertically
oriented track
portions, two on each side of the container. [0028] In either case, the
generally
vertically oriented track portions provide a mechanism for one of the support
member
assemblies supporting a wall of a dunnage pouch to move downwardly out of the
way of
the loader/unloader. With the front support member assembly lower than the
rear
support member assembly supporting a dunnage pouch, the loader/unloader has an
easier time loading or unloading a product into or out of the dunnage pouch
because he
or she does not have to lift the product as far in a vertical direction. This
capability of
the container to ease the loading or unloading procedure may reduce the number
of
injuries and down time and thus, save costs. The drop down door or doors and L-
shaped or U-shaped tracks inside the container allow parts to be removed from
inside
the container with minimal lifting, making /the process of unloading a
container easier
and less stressful on the operator's body than previously known. Similarly,
such
configurations of containers make the process of loading a container with
parts for
shipment easier and less stressful on the operator's body than using
previously known
containers.
[0029] 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.
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Brief Description of the Drawings
[0030] 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.
[0031] Fig.1 is a perspective view of one embodiment of a reusable and
returnable
container;
[0032] Fig. 2 is a cross-sectional view taken along the line 2-2 of Fig. 1
showing
products being suspended by a plurality of pouches;
[0033] Fig. 2A is a cross-sectional view like Fig. 2 showing an alternative
form of
dunnage inside the container of Fig. 1;
[0034] Fig. 3A is a partial cross-sectional view of the container shown in
Figs. 1 and 2,
the door being shown in a lowered or dropped position;
[0035] Fig. 3B is a partial cross-sectional view of the container shown in
Fig. 1, the
front slider assembly being shown in a lowered or dropped position;
[0036] Fig. 3C is a partial cross-sectional view of the container shown in
Fig. 1,
showing the front product being removed;
[0037] Fig. 3D is a partial cross-sectional view of the container shown in
Fig. 1, the
second slider assembly being shown in a lowered or dropped position;
[0038] Fig. 4 is an enlarged view of the encircled area 4 of Fig. 1;
[0039] Fig. 4A is a view taken along the line 4A-4A of Fig. 4;
[0040] Fig. 4B is a cross-sectional view of a portion of an alternative
support member
assembly;
[0041] Fig. 5 is an enlarged view of the encircled area 5 of Fig. 1;
[0042] Fig. 6 is a perspective view of an alternative embodiment of reusable
and
returnable container;
[0043] Fig. 7 is a cross-sectional view taken along the line 7-7 of Fig. 6
with products
shown in the pouches;
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[0044] Fig. 8A is a partial cross-sectional view of the container shown in
Fig. 6, the
door being shown in a raised or up position;
[0045] Fig. 8B is a partial cross-sectional view of the container shown in
Fig. 8A, the
door being shown in a lowered or dropped position;
[0046] Fig. 9 is a perspective view of an alternative embodiment of a reusable
and
returnable container having two doors;
[0047] Fig. 9A is a view taken along the line 9A-9A of Fig. 9 with products
shown in the
pouches;
[0048] Fig. 10 is an enlarged view of a portion of a container showing a bump
at the
front of one of the horizontal tracks;
[0049] Fig. 11 is a perspective view of another embodiment of the reusable and
returnable container;
[0050] Fig. 12 is a cross-sectional view taken along the line 12-12 of Fig. 11
with
products shown in the pouches;
[0051] Fig. 13A is a partial cross-sectional view of the container shown in
Fig. 11, the
door being shown in a lowered or dropped position;
[0052] Fig. 13B is a partial cross-sectional view of the container shown in
Fig. 11,
showing the front product being removed;
[0053] Fig. 13C is a partial cross-sectional view of the container shown in
Fig. 11, the
front slider assembly being shown in a lowered or dropped position;
[0054] Fig. 13D is a partial cross-sectional view of the container shown in
Fig. 11,
showing a second product being removed;
[0055] Fig. 13E is a partial cross-sectional view of the container shown in
Fig. 11, a
second slider assembly being shown in a lowered or dropped position;
[0056] Fig.14 is a perspective view of another embodiment of the reusable and
returnable container;
[0057] Fig. 15 is a cross-sectional view taken along the line 15-15 of Fig. 14
with
products shown in the pouches;
[0058] Fig. 16 is a perspective view of another embodiment of the reusable and
returnable container;
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[0059] Fig.17 is an enlarged perspective view of a portion of the container of
Fig. 16
showing a locking mechanism for the door;
[0060] Fig.18 is an enlarged perspective view of a portion of the container of
Fig. 16
showing the door partially lowered;
[0061] Fig.19 is an enlarged perspective view of a portion of the container of
Fig. 16
showing the door fully lowered;
[0062] Fig.20 is an enlarged perspective view of a portion of an alternative
container
showing the door partially lowered;
[0063] Fig.21 is an enlarged perspective view of a portion of the container of
Fig. 20
showing the door locked in a raised position;
[0064] Fig.22 is an enlarged perspective view of a portion of an alternative
container
showing a corner of a continuous track;
[0065] Fig. 23 is a perspective view of an alternative embodiment of a
reusable and
returnable container having two doors;
[0066] Fig. 24 is a cross-sectional view taken along the line 24-24 of Fig. 23
with
products shown in the pouches;
[0067] Fig. 25 is a rear perspective view of an alternative embodiment of
container
showing a different type of track and a different type of support member
assembly;
[0068] Fig. 26 is an enlarged view of a portion of two support member
assemblies and
associated dunnage of the container of Fig. 25;
[0069] Fig. 27 is a cross-sectional view taken along the line 27-27 of Fig.
26;
[0070] Fig. 28 is a cross-sectional view of an alternative shape of track and
end
member;
[0071] Fig. 29 is a perspective view of another embodiment of reusable and
returnable
container incorporating a metal frame or rack;
[0072] Fig. 30 is a perspective view of the metal frame of the container of
Fig. 29;
[0073] Fig. 31 is a perspective view of the metal frame and guide assembly of
the
container of Fig. 29;
[0074] Fig. 32 is a partially dissembled view of a portion of the container of
Fig. 29;
[0075] Fig. 33 is a partially dissembled view of a portion of the container of
Fig. 29;
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[0076] Fig. 34 is a cross-sectional view taken along the line 34-34 of Fig. 29
with
products shown in the pouches;
[0077] Fig. 35 is a partially dissembled view of a portion of the container of
Fig. 29;
[0078] Fig. 36 is a partially dissembled view of a portion of the container of
Fig. 29;
[0079] Fig. 37 is a partially dissembled view of a portion of another
embodiment of
reusable and returnable container incorporating a metal rack; and
[0080] Fig. 38 is a partially dissembled view of a portion of another
embodiment of
reusable and returnable container of Fig. 37.
Detailed Description of the Invention
[0081] 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 and a rear wall
18, all
extending upwardly from the base 14. The side walls 16 and/or rear wall 18 may
be
hingedly secured to the base 12. A generally U-shaped front frame 20 may be
fixedly
secured to the side walls 16 and does not move relative to the side walls 16
after the
container is assembled. The front frame 20 may be made of metal or any other
suitable
material.
[0082] As shown in Fig. 2, a bumper 17 may be secured to each of the side
walls 16
(only one being shown). Each bumper 17 functions to protect the products 40
from
contacting the side walls 16 and being scratched or damaged in some fashion.
The
bumpers may be made of foam or any other suitable material. If desired, the
bumpers
may be omitted.
[0083] Although one specific shape of product 40 is illustrated in the
drawings, this
document is not intended to limit in any way the size, shape or configuration
of product
40 shipped or stored in any of the embodiments described or shown herein. One
type
of product which may be used in accordance with the present invention is car
door
panels.
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[0084] Although one type of container is illustrated, the present invention
may be used
with other types or configurations of container. For example, each side wall
may not be
a solid wall.
[0085] As best shown in Fig. 1, the front frame 20 comprises a frame base 22
and two
side posts 24 extending upwardly from the frame base 22. The frame base 22 is
fixedly
secured to the base 14 of the container 10 with rivets or fasteners 21, while
the side
posts 24 of the front frame 20 are secured to the container side walls 16.
[0086] Each of the side posts 24 of the front frame 20 is generally
rectangular in cross-
section and has a hollow interior 25. Each of the side posts 24 of the front
frame 20 has
two slots therethrough, an upper slot 26 and a lower slot 28. However, any
number of
slots of any desired shape may be incorporated into the side posts. As best
shown in
Figs. 3A-3D, upper slot 26 has a "candy cane" shape comprising a straight
portion 30
and a curved upper portion 32. The lower slot 28 is linear, as best
illustrated in Fig. 2.
These upper and lower slots 26, 28 are used to secure a movable door 34 in a
fixed
position and guide the door 34 during its movement from an upper or raised
position and
a lower or dropped position. As best shown in Figs. 2 and 3A-3D, the door 34
has a pair
of upper pins 36 extending outwardly from the door 34 and adapted to ride or
move
inside the upper slots 26. Similarly, the door 34 has a pair of lower pins 38
extending
outwardly from the door 34 and adapted to ride or move inside the lower slots
26. Fig. 2
shows the door 34 locked in a raised position with the upper pins 36 located
at the
upper ends of the curved portions 32 of the upper slots 26. As the door 34 is
lowered, it
moves outside a shield 42 secured with rivets or fasteners 41 to a vertically
oriented
flange 44 of the base 22 of the front frame 20. See Fig. 2.
[0087] As best shown in Fig. 1, a pair of spaced stops 45 are secured to door
34. The
stops 45 may be made of foam or any other suitable material. When the door 34
is in its
raised position, stops 45 function to prevent the support member assemblies
and
associated dunnage from sliding down the vertically oriented tracks from the
horizontally
oriented tracks. The stops 45 also function to prevent products 40 from
hitting the door
34 during the loading or unloading process. Although two stops 45 are
illustrated per
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door 34, a continuous stop or a different number of stops may be utilized of
any desired
configuration or size.
[0088] As best shown in Fig. 2, container 10 further comprises a generally "L-
shaped"
track 5 secured to each side wall 16 of the container 10, which does not move
relative to
the side wall 16 after the container 10 is assembled and during the loading or
unloading
processes (only one being shown in Fig. 2). Each "generally L-shaped" track 5
comprises a generally horizontally oriented track portion 46 and a generally
vertically
oriented track portion 60, each being fixedly secured to a side wall 16 of the
container
10. Each "generally L-shaped" track 5 may be constructed of several pieces or
may be
a unitary piece. As shown in Fig. 4, each generally horizontally oriented
track portion 46
and each generally vertically oriented track portion 60 has an upper wall 48,
a lower wall
50 joined to the upper wall 48 by a side wall 52, and a lip 54 extending
downwardly from
the upper wall 48 and another lip 56 extending upwardly from the lower wall 50
defining
an interior 58 of the track 46.
[0089] As best shown in Figs. 3A-3D, generally vertically oriented track
portion 60 of
"generally L-shaped" track 5 is also fixedly secured to each side wall 16 of
the container
10. The generally vertically oriented track portion 60 and generally
horizontally oriented
track portion 46, each being fixedly secured to the side walls 16 of the
container 10, do
not move after the container 10 is assembled and do not move relative to the
side walls
16 of the container 10 during the loading or unloading of parts or products.
On each
side of the container, the top of the generally vertically oriented track
portion 60 may
connect or communicate with the front end of the generally horizontally
oriented track
portion 46 at corner 62. The generally vertically oriented track portion 60
may be the
same construction and/or material as the horizontally oriented track portion
46, or they
may be slightly different. The interior 58 of the generally horizontally
oriented track
portion 46 connects with the interior of the generally vertically oriented
track portion 60
so that one of the support member assemblies 66 may move along a continuous
path in
both a horizontal and vertical direction. The generally horizontally oriented
track portion
46 and generally vertically oriented track portion 60 may be separate pieces
welded or
joined together, or may be a unitary generally "L-shaped" piece of track
fixedly secured
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to each of the side walls 16. In either event, a corner piece 64 may be welded
or
otherwise secured to each corner 62 to prevent the end members or portions of
the
support member assemblies 66 from coming out of the tracks at the corner.
[0090] Referring to Fig. 4, container 10 further comprises a plurality of
support member
assemblies 66 extending between the tracks of opposed side walls 16. Each
support
member assembly 66 includes a pair of sliders or end members 68 and a tubular
support 70 having a hollow interior 72 extending therebetween. The sliders 68
are
preferably made of injection molded plastic, such as nylon, but may be made of
any
other material. The tubular support 70 is preferably made of metal, but may be
made of
other suitable material, such as plastic.
[0091] As shown in Fig. 4, each slider 68 preferably has a first portion 74
having an X-
shaped cross-sectional configuration and a second portion 76 having a circular
cross-
sectional configuration. Although one configuration of slider 68 is
illustrated, any type or
configuration of slider may be used with the present invention. In this
embodiment,
each slider 68 has a pair of heads 78, 80 at the end of the slider 68. Head 78
is furthest
from the first portion 74 of the slider 68, and head 80 is spaced inwardly
from head 78.
The heads 78, 80 are spaced from one another to define a groove 82
therebetween
which receives and retains the lips 54, 56 of the stationary tracks 46, 60. As
shown in
Fig. 4, head 78 is located inside the interior 58 of tracks 46, 60 and head 80
is located
outside the interior 58 of stationary tracks 46, 60. Head 78 keeps the slider
66 engaged
with the tracks 46, 60 while head 80 keeps the dunnage material out of the
interior 58 of
the tracks 46, 60, thereby ensuring that the sliders 66 may move smoothly
along the
stationary tracks. Although one configuration of support member assembly 66 is
illustrated, the present invention may be used with any type or configuration
of support
member assembly for supporting dunnage so the dunnage may slide or move inside
the
container.
[0092] As shown in Fig. 4, each end of tubular support 70 fits over at least
one portion
74 of a slider 66. An end surface 84 of tubular support 70 abuts head 80 of
slider 66.
Each end member or slider 68 of each support member assembly 66 is adapted to
engage and move along one of the tracks. The end members 68 preferably slide
along
CA 02826768 2013-09-10
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.
[0093] As best shown in Fig. 4A, support member assembly 66 includes a pair of
sliders 68 (only one being shown in Fig. 4A). Each slider 68 has a groove 86
formed in
a portion 76 therein. Support member assemblies 66 further include a tubular
support
70 having a hollow interior 72 extending therebetween. The tubular support 70
is
preferably made of metal, but may be made of other suitable material, such as
plastic.
As shown in Fig. 4A, each end of tubular support 70 fits over at least one
portion 74 of a
slider 68. An end surface 84 of tubular support 70 abuts head 80 of slider 68.
As
shown in Fig. 4A, tubular support 70 has two detents 89 therethrough (one at
each end)
in which the material of the tubular support is pressed downwardly into the
groove 86.
This attachment between each of the two sliders 68 and the tubular support 70
enables
some movement therebetween. Such interaction between the sliders 68 and
tubular
support 70 allows for a tolerance of approximately one-quarter inch on each
side. The
detents 89 prevent separation of the tubular support 70 from the sliders 68
while
allowing some movement therebetween as the detents 89 move within the grooves
86
formed in the sliders 68.
[0094] As shown in Fig. 4B, a slightly different support member assembly 66',
including
a pair of sliders 68 (only one being shown in Fig. 4B), may be used. Support
member
assembly 66' is slightly different than support member assembly 66 shown in
Fig. 4A
and described above. As shown in Fig. 4B, the only difference between support
member assembly 66' and support member assembly 66 shown in Fig. 4A is that
tubular
supports 70' are slightly different than the tubular supports 70; they lack
detents 89.
See Fig. 4A. Each support member assembly 66' includes a tubular support 70'
having
a hole 88 at each end. The tubular support 70' is preferably made of metal,
but may be
made of other suitable material, such as plastic. As shown in Fig. 4B, each
end of
tubular support 70' fits over at least one portion 74 of a slider 68. An end
surface 84 of
tubular support 70' abuts head 80 of slider 68. As shown in Fig. 4B, tubular
support 70'
has holes 88 therethrough, which receive fasteners 90. Although fasteners 90
are
CA 02826768 2013-09-10
16
shown as screws, they may be any other type of fasteners. The fasteners 90
prevent
separation of the tubular support 70' from the sliders 68 while allowing some
movement
therebetween as the fastener 90 moves within the grooves 86 formed in the
sliders 68.
Other known means of securing the tubular support 70 to the sliders 68 may be
used if
desired.
[0095] Figs. 1 and 4 illustrate all of the support member assemblies 66 having
detents
89, as shown in Fig. 4A. Alternatively, containers may be made with all of the
support
member assemblies having fasteners, like support member assemblies 66'.
Alternatively, some of the support member assemblies may have fasteners like
support
member assemblies 66', and some may have detents like support member
assemblies
66. Containers may have a mixture thereof.
[0096] Fig. 5 illustrates another support member assembly 66, exactly like the
one
shown in Fig. 4A, used to support one of the pouches. However, Fig. 5
illustrates
another innovative feature or aspect of the invention. Track portion 46 has an
opening
or cut-out 92 formed therein. Holes 94 are formed in the upper wall 48 of
track portion
46, which are sized and threaded to receive fasteners 96. Although fasteners
96 are
illustrated to be screws, they may be any other desirable fastener. A cap 98
is
removably secured to the track portion 46 to cover the opening or cut-out 92
formed in
an upper portion of track portion 46. As best seen in Fig. 5, cap 98 has a
generally
inverted U-shaped cross-sectional configuration, including a top portion 100
and side
portions 102 extending downwardly from the top portion 100. Holes 104 are
formed
through the top portion 100 of the cap 98 and sized to receive fasteners 96,
as shown in
Fig. 5. The fasteners 96 are adapted to pass through the holes 104 in the cap
98 and
into the holes 94 in the upper wall 48 of the track portion 46. Caps of
alternative shapes
or sizes may be used if desired.
[0097] When one of the sliders 68 or any part of support member assemblies 66,
66'
are damaged or need to be replaced for any reason, one may remove cap 98 after
loosening fasteners 96, thereby exposing the opening or cut-out 92 of track
portion 46.
The support member assemblies 66, 66' may then be removed or inserted as
necessary
to repair or replace the damaged part or parts.
CA 02826768 2013-09-10
17
[0098] As best shown in Fig. 2, dunnage 106 in the form of a plurality of
pouches 108
are suspended by and supported by a plurality of support member assemblies 66.
Each
pouch 108 has a front wall 109, a rear wall 111 and a bottom 113 extending
therebetween. As shown in Fig. 2, the top of the front wall 109 is attached to
one of the
support member assemblies 66 and the rear wall 111 being attached to an
adjacent
support member assembly 66. Although the dunnage 106 shown comprises pouches,
the dunnage may assume other shapes or configurations. A pouch 108 is
supported by
two adjacent support member assemblies 66. As shown in Fig. 4, the fabric of
the
pouch 108 is sewn or otherwise secured together along a seam 110 to make a
pocket
112 in which is located a tubular support 70 of the support member assembly
66.
[0099] Support member assemblies 66 supporting pouches 108 are adapted to move
from back to front inside the interior of the container 10, the end members or
sliders 68
of the support member assemblies 66 moving along the stationary tracks 5 in
generally
horizontal and generally vertical directions.
[0100] Multiple pouches 108 may be formed or created from one piece of
material
draped or laying over and secured to the support member assemblies 66.
Alternatively,
each pouch 108 may be made from its own piece of material, in which case, the
pouches 108 would not be interconnected other than via the straps or space
limiters
114.
[0101] The reusable and returnable container 10 may also have at least one
space
limiter or strap 114 which, as shown in Figs. 2 and 3A-3D, limits the distance
the support
member assemblies 66 may be moved away from one another due to the fact that
each
space limiter 114 is secured to the dunnage of adjacent support member
assemblies 66.
Typically, the length or distance of the space limiter 114 between locations
where the
space limiter 114 is secured to the dunnage will be fixed to prevent the
support member
assemblies 66 from moving farther apart than necessary for the insertion or
removal of
product 40 into or from the pouches. The space limiter 114 may be secured to
the
dunnage 106 in any suitable fashion including, but not limited to, sewing,
fastening, etc.
Of course, when the support member assemblies 66 are moved to a position
adjacent
to one another, the flexibility of the space limiters 114 allows for such
movement. The
CA 02826768 2013-09-10
18
space limiter 114, as shown, is preferably comprised of a fabric strap, but
may be made
of any other suitable material, such as plastic. Preferably, two space
limiters or straps
114, one on each side of a pouch 108, connect adjacent walls 109, 111 of a
pouch 108.
However, any number of straps 114 may be used to connect any number of
pouches.
[0102] As shown in Fig. 2A, straps 114 may be omitted and replaced with two
side
sewn locations 172 (only one being shown in Fig. 2A). Each pouch 108 has two
sewn
locations 172 on opposite sides of the pouch 108, thereby enabling the product
40 to be
inserted or removed as desired. Each sewn location 172 comprises the front and
rear
walls 109,111 of pouch 108 being sewn together at a specific location.
[0103] Figs. 3A-3D illustrates a method of unloading product 40 from the
pouches 108
of the container 10. The method comprises the step of lowering door 34 from a
raised
and locked position shown in Fig. 2 to a lowered or dropped position
illustrated in Fig.
3A. As shown in Fig. 3A, when the door 34 is in a lowered position, an opening
having a
height Hi is created above the door 34. The next step comprises moving the
first
support member assembly 66 forwardly, the sliders 68 sliding in the stationary
generally
horizontally oriented track portions 46, and then down the stationary
generally vertically
oriented track portions 60 until the straps 114 extending between the front
and rear walls
of the front pouch 108 are stretched and generally linear, as shown in Fig.
3B. At this
point, the product 40 in the forwardmost or front pouch 108 is still in the
front pouch 108,
as shown in Fig. 3B. As shown in Fig. 3C, the product 40 in the front pouch
108 is then
removed by the operator in the direction shown by arrow 116 over the front
door 34.
Thus, the front product 40 being removed passes between the partially lowered
or
dropped first support member assembly 66 and the second support member
assembly
66, which is still extending between the generally horizontally oriented track
portions 46.
As shown in Fig. 3C, the lowered position of the front door 34 makes it easier
from an
ergonomic standpoint for the operator to remove the product 40 because the
product 40
need not be raised over the full height of the container 10 to be removed from
inside the
container. Fig. 3D illustrates the second support member assembly 66 extending
between the stationary generally vertically oriented track portions 60 above
the front
support member assembly 66, the straps 114 extending between the front and
rear
CA 02826768 2013-09-10
19
walls of the second pouch 108 being stretched and generally linear. The front
support
member assembly 66 is spaced above the bottom of the container by a bottom
stop
118. With the second support member assembly 66 extending between the
vertically
oriented tracks 60 as shown in Fig. 3D, the product 40 in the second pouch 108
may be
easily removed like the front product 40 was removed. This process is
continued by an
operator until all the products 40 are removed from the pouches 108 and each
of the
support member assemblies 66 extend between the generally vertically oriented
track
portions 60. The empty container 10 still having the dunnage therein is then
shipped
back to its desired location for loading additional products. During the
unloading or
loading process, the tracks 5 remain stationary fixedly secured to the
container side
walls 16; it is the support member assemblies 66 and dunnage 106 hanging from
the
support member assemblies 66 which move inside the container with the
assistance of
an operator. The loading process is the reverse.
[00104] Figs. 6, 7, 8A and 8B illustrate an alternative embodiment of
container 10a.
Container 10a has a stationary U-shaped front frame 20a fixedly secured to the
container side walls 16. In this embodiment, the front frame 20a comprises a
base 22a
and two side posts 24a extending upwardly from the frame base 22a. The frame
base
22a is fixedly secured to the base 14 of the container 10a with rivets or
fasteners 21,
while the side posts 24a of the front frame 20a are fixedly secured to the
container side
walls 16. During the loading or unloading processes described herein, the
front frame
20a does not move.
[0105] Each of the side posts 24a of the front frame 20a is generally
rectangular in
cross-section and has a hollow interior 25a. Each of the side posts 24a of the
front
frame 20a has two slots therethrough; an upper slot 26a and a lower slot 28a.
As best
shown in Figs. 7, 8A and 8B, upper slot 26a has a "candy cane" shape
comprising a
straight portion 30a and a curved upper portion 32a. The lower slot 28a is not
linear, but
rather has a "Z" shape, as best illustrated in Fig. 7. These upper and lower
slots 26a,
28a are used to secure a movable multi-segmented or multi-piece door or door
assembly 34a in a fixed position and guide the door assembly 34a during its
movement
from an upper or raised position and a lower or dropped position.
CA 02826768 2013-09-10
[0106] As best shown in Figs. 7 and 8A-8B, the movable door assembly 34a
comprises a movable upper segment 120 and a movable lower segment 122 which
are
not connected together. As shown in Fig. 7, the upper segment 120 has a flange
124 at
the bottom thereof. The upper segment 120 has a pair of upper pins 36a
extending
outwardly from the upper segment 120 of the door assembly 34a and adapted to
ride or
move inside the upper slots 26a. In addition, the upper segment 120 of the
door
assembly 34a has an integral U-shaped upper handle 128 which a user may easily
grasp and move the upper segment 120 of the door assembly 34a along with the
lower
segment 122 of the door assembly 34a due to the configuration of the door
assembly
34a. Similarly, the upper segment 120 of door 34a has a pair of lower pins 38a
extending outwardly from the upper segment 120 of door assembly 34a and
adapted to
ride or move inside the lower slots 28a. Fig. 7 shows the door assembly 34a
locked in a
raised position with the upper pins 36a located at the ends of the curved
portions 32a of
the upper slots 26a.
[0107] The lower segment 122 of door assembly 34a is not fastened or secured
to any
particular piece and is free floating between the generally vertically
oriented track
portions 60 and the upper segment 120 of door assembly 34a. The lower segment
122
of door assembly 34a has a U-shaped lip 126 located at the upper end of the
lower
segment 122. The lower segment 122 of door assembly 34a moves inside a
stationary
vertically oriented flange 43 of the base 22 of the front frame 20a. As the
door 34a is
lowered, the lower segment 122 of door assembly 34a moves inside a flange 43
of the
base 22a of the front frame 20a. As the door assembly 34a is raised, the
flange 124 of
the upper segment 120 of door assembly 34a contacts the U-shaped lip 126
located at
the upper end of the lower segment 122 and raises the lower segment 122 of
door
assembly 34a.
[0108] When the door assembly 34a is in its lowered position shown in Fig. 8B,
an
opening having a height H2 is created above the door assembly 34a. The height
H2 of
the opening is greater than the height H1 of the embodiment shown in Figs. 1
and 2
(approximately half the height of the container). Thus, the opening H2 is
greater than
CA 02826768 2013-09-10
21
half the height of the container H1, making it more desirable from an
ergonomic
standpoint for the loader/unloader.
[0109] Fig. 9 shows another alternative embodiment of container 10b. This
container
10b has two doors 34a on opposite sides of the container. Each door 34a is
like the
door 34a shown in Figs. 6, 7, 8A and 8B. Any of the containers shown or
described
herein may have two doors and two generally vertically oriented stationary
track portions
attached to each side wall of the container and extending downwardly from a
generally
horizontally oriented track portion, one generally vertically oriented track
portion being
proximate each of the doors.
[0110] Fig. 9A shows the interior of container 10b. On each side of the
container,
rather than one stationary generally vertically oriented track portion 60, two
stationary
generally vertically oriented track portions 60 extend downwardly from the
ends of a
stationary generally horizontally oriented track portion 46 to create a
generally "U-
shaped" track 7 fixedly secured to each side wall 16 (only one being shown in
Fig. 9A).
With such an interior, support member assemblies 66 with dunnage may be moved
towards either end of the container to load or unload products from either end
of the
container over a lowered door, the support member assemblies 66 moving along
either
one or both of the stationary vertically oriented tracks 7.
[0111] Fig. 10 shows a feature of container 10 which may be used in any
embodiment
or container shown or described herein. This feature comprises a bump 130 at
one end
of the stationary horizontally oriented track 46. The purpose of the bump 130
is to
prevent support member assemblies 66 from accidently passing from the
generally
horizontally oriented track portion 46 to the stationary generally vertically
oriented track
portion or portions 60. Containers having two generally vertically oriented
track portions
60 on each side of the container would have two bumps 130; one on each end of
each
generally horizontally oriented track portion 46, making a total of four bumps
130 per
container.
[0112] Figs. 11, 12 and 13A-13E illustrate an alternative embodiment of
container 10c.
Inside container 10c, the front edge of dunnage 106 is secured to door 34c. As
best
illustrated in Fig. 12, door 34c is identical to door 34, except door 34c has
a bar 132
CA 02826768 2013-09-10
. .
22
around which the front edge of the front wall of the front pouch 108 is
wrapped and
sewn or secured. Fig. 12 shows the door 34c in a raised position, the front
edge of the
front pouch 108 being secured to bar 132 of door 34c. Other than bar 132 of
bar 34c
and the dunnage being secured thereto, container 10c is identical to container
10 shown
and described herein.
[0113] Figs. 13A-13E illustrates a method of unloading product 40 from the
pouches
108 of the container 10c. The method comprises the step of lowering door 34c
from a
raised and locked position shown in Fig. 12 to a lowered or dropped position
illustrated
in Fig. 13A. When the door 34c is down in its lowered position shown in Fig.
13A, the
upper end of the front wall 109 of the front pouch 108 is below the rear of
the front
pouch 108. At this point, the product 40 in the front pouch 108 is still in
the front pouch
108, as shown in Fig. 13A. As shown in Fig. 13B, the product 40 in the front
pouch 108
is then removed from inside the front pouch 108 over the lowered door 34c by
the
operator in the direction shown by arrow 134. Thus, the front product 40 being
removed
passes between the lowered or dropped door 34c and the first support member
assembly 66, which is still in the stationary generally horizontally oriented
track portion
46. As shown in Fig. 13B, the lowered position of the front door 34c makes it
easier
from an ergonomic standpoint for the operator to remove the product 40 because
the
product 40 need not be raised the full height of the container 10c. As shown
in Fig.
13C, the next step comprises moving the first or front support member assembly
66
forwardly in the track portion 46 in the direction of arrow 136, the sliders
68 sliding in the
stationary generally horizontally oriented track portions 46. As shown in Fig.
13D, front
support member assembly 66 is then moved downwardly in the stationary
generally
vertically oriented track portions 60, the sliders 68 sliding down the
generally vertically
oriented track portions 60 until the straps 114 located in the second pouch108
are
stretched and generally linear. Fig. 13D illustrates the front support member
assembly
66 extending between the generally vertically oriented track portions 60, the
straps 114
extending between the first or front and second support member assemblies 66
being
stretched and generally linear. Fig. 13E illustrates the second support member
assembly 66, like the first support member assembly 66 extending between the
CA 02826768 2013-09-10
23
generally vertically oriented track portions 60, the front support member
assembly 66 is
spaced above the bottom of the container by a bottom stop 118. With the second
support member assembly 66 extending between the generally vertically oriented
track
portions 60, as shown in Fig. 13E, the product 40 in the third pouch 108 may
be easily
removed like the other product 40 in the other pouches were removed. This
process is
continued by an operator until all the product 40 are removed from their
pouches 108,
and each of the support member assemblies 66 extend between the generally
vertically
oriented track portions 60. The empty container 10c still having the dunnage
therein is
then shipped back to its desired location for loading additional products. The
loading
process is the reverse. During the unloading or loading process, the location
of the
track portions 46, 60 remains stationary; it is the support member assemblies
66 and
dunnage 106 hanging from the support member assemblies 66 which move inside
the
container with the assistance of an operator. This process may be used in any
of the
containers shown or described herein, the dunnage being secured to one or two
doors
of the container.
[0114] Figs. 14 and 15 illustrate an alternative embodiment of container 10d.
As
shown in Fig. 15, inside container 10d, the front edge of dunnage 106 in the
form of
pouches 108 for supporting products 40 is secured to door 34d. Door 34d is
identical to
door 34a, except door 34d has a bar 138 around which the front edge of the
front pouch
108 is wrapped and sewn or secured. Fig. 14 shows the door 34d in a raised
position,
the front edge of the front pouch 106 being secured to bar 138 of door 34d.
Other than
bar 138 of door 34d and the dunnage being secured thereto, container 10d is
identical
to container 10a shown and described herein.
[0116] Figs. 16-19 illustrate an alternative embodiment of container 10e. In
container
10e, door 34e slides in stationary vertically oriented tracks 140 (one on each
side wall)
between a raised and locked position shown in Figs. 16 and 17, and a lowered
position
shown in Fig. 19. As shown in Fig. 18, at the top of each track 140 is a hole
142
adapted to receive a pin 144 from a lock 146. A ring 148 is attached to pin
144 at each
end of the door 34e. The locks 146, only one being shown, are located at the
sides of
the door 34e and move with the door 34e. A connector 150, which may be in the
form
CA 02826768 2013-09-10
24
of a wire or any other suitable material, extends between the rings 148. In
order to
disengage the pins 144 from inside the holes 142 and lower the door 34e, an
operator
may pull on the connector 150, thereby moving the pins 144 toward each other
out of
engagement with the holes 142. With the pins 144 no longer holding the door in
an
upward raised and locked position, the door 34e may be moved downwardly inside
tracks 140 to the position shown in Fig. 19. Although Figs. 1 6-1 9 illustrate
container 10e
having only one door 34e, this door 34e may be located on opposite sides of a
container. In such a container, two tracks would be located inside the
container, one for
each door. [0116] Figs. 20 and 21 illustrate a container 10f having a door 34f
having
an additional feature which may be used to help hold door 34f in a raised and
locked
position. This feature comprises a movable finger 152, which may be located at
the top
of each track 140. The finger 152 is adapted to engage a slot 154 located at
the top of
the door 34e. This feature may be used in any of the containers described or
shown
herein.
[0117] Fig. 22 illustrates a unitary "L-shaped" track 155 having a rounded
corner which
is fixedly secured to one of the side walls 16. The unitary track 155
comprises a
horizontal portion 156 and a vertical portion 158 connected by a curved
portion 160.
Although the unitary tracks 155 are illustrated in container 10e, they may be
used in any
of the containers illustrated or described herein. Such rounded corners may be
used in
any tracks described or shown herein and may be used in containers having one
or two
vertically oriented tracks.
[0118] Figs.
23 and 24 illustrate an alternative embodiment of container 10g.
Container 10g is a two-sided container having a U-shaped frame 20 fixedly
secured to
the container side walls 16 at each end of the container 10g which does not
move
during the loading or unloading of the container. In this embodiment, each
frame 20 is
identical to the frame disclosed in container 10. The container 10g has two
movable
doors 34, one at each end, identical to the door 34 shown in the embodiment of
Figs 1
and 2.
[0119] Inside container 10g, a "U-shaped" unitary track 165 having a
horizontal portion
166 and two vertical portions 168 connected by two curved portions 170,
similar to the
CA 02826768 2013-09-10
track shown in Fig. 22, is secured to each side wall 16 in a fixed, stationary
position
(only one being shown in Fig. 24). Support member assemblies 66, like those
described
herein and shown in other embodiments, may move inside container 10g in both a
vertical and horizontal direction due to the location and configuration of
tracks 165 on
side walls 16. Such stationary tracks may be used in any container shown or
described
herein.
[0120] Fig. 25 illustrates an alternative embodiment of container 10h having
only one
door 34e configured and operational like the door shown in Figs. 16-19. This
embodiment of container 10h may use any door or features described or
illustrated
herein.
[0121] This
container 10h illustrates a different generally "L-shaped" track 174
attached to and spaced from each side wall 16 with fasteners 175 (only one
track 174
being shown in Fig. 25). As shown in Fig. 25, each track 174 comprises a
horizontal
portion 176 and a vertical portion 178 joined by a curved corner 180. As shown
in Fig.
27, each of the fasteners 175 extends through one of the side walls 16 and
into a track
rail 182 which is shown as circular in cross-section in Figs. 26 and 27.
However, as
exemplified in Fig. 28, the track rail 182 may be rectangular or oval or any
desired shape
of cross-sectional configuration. Fig. 28 illustrates a track rail 183 having
a rectangular
cross-section secured to side wall 16 with fastener 175 in the same manner.
The
fasteners 175 space the track rail 182, 183 away from the inner surface of the
side wall
16 to provide clearance for a portion of an end member or slider 184 to move
past the
fasteners 175. As best shown in Fig. 27, each slider 184 has a generally "C-
shaped"
portion 186 which partially surrounds the track rail 182 and an inward portion
76h. Fig.
28 illustrates a slider 185 having a slightly different configuration
partially surrounding
track rail 183.
[0122] In container 10h, each support member assembly 66h comprises two end
members or sliders 184 attached to a tubular support 70 in any manner
described
herein. As best shown in Fig. 26, support member assembly 66h includes a pair
of
sliders 184 (only one being shown in Fig. 26). Each slider 184 has a groove 86
formed
in a portion 76h therein. Support member assemblies 66h further include a
tubular
CA 02826768 2013-09-10
26
support 70 having a hollow interior 72 extending therebetween. As shown in
Fig. 27,
each end of tubular support 70 fits over at least one portion of a slider 184.
As shown in
Fig. 27, tubular support 70 has two detents 89 therethrough (one at each end)
in which
the material of the tubular support 70 is pressed downwardly into the groove
86 at each
end. This attachment between each of the two sliders 184 and the tubular
support 70
enables some movement therebetween. Such interaction between the sliders 184
and
tubular support 70 allows for a tolerance of approximately one-quarter inch on
each
side. The detents 89 prevent separation of the tubular support 70 from the
sliders 184
while allowing some movement therebetween as the detents 89 move within the
grooves 86 formed in the sliders 184. This may be true no matter what the
shape of the
mating slider and track rail.
[0123] Although a generally "L-shaped" track 174 is shown and described, a
generally
"U-shaped" track like the track 174 may be used in any container described or
shown
herein. Any combination of features described or shown herein may be used in
combination with any other features described or shown herein. For example,
the
container shown in Fig. 25 may have two doors and generally "U-shaped" tracks
spaced
from the side walls like tracks 174.
[0124] Figs. 29-33 illustrate an alternative embodiment of container 10i. As
best
shown in Fig. 30, container 10i comprises an outer metal rack or frame 186
having a
bottom 188 and four corner posts, two rear corner posts 190a and two front
corner posts
190b. Each of the corner posts 190a and 190b is generally rectangular in cross-
section,
has a hollow interior, a knob 191 at the top thereof and a cap 189 at the
bottom thereof
for stacking purposes so that multiple containers 10i may be stacked upon one
another.
The knobs 191 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.
The metal frame 186 further comprises rear members 192, 193 extending between
the
two rear corner posts 190a. The rear members 192, 193 and rear corner posts
190a
define a rear portion 194 of the metal frame 186, rear member 193 being below
two rear
members 192. In some applications, the lower rear member 192 may be omitted
for
weight reduction.
CA 02826768 2013-09-10
27
[0125] The metal frame 186 further comprises, on each side of the container,
side
members 196, 198 and 200 extending between one of the rear corner posts 190a
and
one of the front corner posts 190b, the side members 196, 198 and 200 and
corner
posts 190a, 190b defining a side portion 202 of the metal frame 186. Side
member 198
is below two side members 196, and side member 200 is below side member 198.
In
some applications, on each side, the lower side member 196 and member 198 may
be
omitted for weight reduction.
[0126] The bottom 188 of the metal rack 186 further comprises four perimeter
members 204 defining a rectangle and a plurality of intersecting interior
members 206
extending between opposed perimeter members 204, members 204 and 206
comprising
part of the bottom 188 of the metal rack 186. Although four interior members
206 are
shown in the bottom 188 of the metal rack 186, any number of interior members
may be
used. Similarly, although the rear and side portions 194, 202 of the metal
rack 186 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.
[0127] As best shown in Fig. 31, container 10i further comprises a metal
generally U-
shaped door guide assembly 208 comprising two opposed door guides 210 and a
panel
211extending between the door guides 210 and welded thereto. The panel 211 has
a
bottom flange 213 which may be secured to the front perimeter member 204 of
the
bottom 188 of the metal rack 186 using welding or fasteners or any other known
technique. For example, the bottom flange 213 of the panel 211 is illustrated
having
holes 215 through which fasteners may pass. Each door guide 210 has a flange
212
which has holes 214 therethrough so the door guide 210 may be secured via
bolts or
any other conventional manner to the outer frame 186.
[0128] Each of the metal guides 210 has two slots therethrough, an upper slot
26a and
a lower slot 28a just like the slots shown and described above. However, any
number of
slots of any desired shape may be incorporated into the metal guides 210. As
best
shown in Figs. 31 and 32, upper slot 26a has a "candy cane" shape comprising a
straight portion 30a and a curved upper portion 32a. The lower slot 28a is not
linear, but
CA 02826768 2013-09-10
28
rather has a "Z" shape, like the lower slot illustrated in Fig. 7. These upper
and lower
slots 26a, 28a are used to secure a movable multi-segmented or multi-piece
door
identical to the multi-piece door assembly 34a having door segments 120, 122
shown
and described herein, particularly in Figs. 6-9A. These slots 26a, 28a guide
the door
assembly 34a during its movement from an upper or raised position and a lower
or
dropped position. If desired, the metal guides 210 may have slots of other
configurations shown and described herein, including the slot system,
including slots 26,
28 shown in Figs. 1-3D adapted to guide a door panel or assembly, such as the
door
panel 34 shown and described herein.
[0129] As best shown in Fig. 32, container 10i further comprises a generally
"L-
shaped" track 5 secured to each side portion 202 of the metal frame 186 of
container
10i, which does not move relative to the side portion 202 of the metal frame
186 after
the container 10i is assembled and during the loading or unloading processes
(only one
track 5 being shown in Fig. 32). Each "generally L-shaped" track 5 comprises a
generally horizontally oriented track portion 46 and a generally vertically
oriented track
portion 60, the generally horizontally oriented track portion 46 being fixedly
secured to
one of the side members 196 of one of the side portions 202 of the outer frame
186 of
container 10i and the generally vertically oriented track portion 60 being
fixedly secured
to at least one of the side members 196, 198, 200 of one of the side portions
202 of the
outer frame 186 of container 10i. Each "generally L-shaped" track 5 may be
constructed
of several pieces or may be a unitary piece and may be constructed in
accordance with
any of the tracks shown or described herein.
[0130] As shown in Fig. 32, each of the tracks 5 has multiple plates 218
welded thereto
for securing the different pieces of container 10i together. Each of the
plates 218 has
an opening 220 therethrough so a fastener may extend through the plate 218.
For
example, the track 5 shown in Fig. 32 has two plates 218 attached to the
vertically
oriented track portion 60 of track 5 and two plates 218 attached to the
generally
horizontally oriented track portion 46 of track 5. Any number of plates may be
used; this
document is not intended to limit the number of plates which are part of the
track 5. Fig.
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29
33 illustrates one side of container 10i partially assembled, the outer frame
186, door
guide assembly 208 and track 5 being secured together.
[0131] As shown in Fig. 36, a floor or panel 222 resides on the bottom 188 of
the metal
rack 186 on the inside thereof. The floor 222 has four openings 224 at the
corners
thereof for drainage and/or handling purposes. The floor 222 may or may not be
secured to the bottom 188 of the metal frame 186. The floor 222 is preferably
made of
plastic, but may be made of any desired material.
[0132] As shown in Fig. 35, a side piece or guard 226 is secured to each side
portion
202 of the metal rack 186 on the inside thereof (only one being shown).
Although
preferably made of plastic, these members 226 may be made of any other
suitable
material. Fasteners 228 extend through openings 230 in the side piece 226,
through the
openings 220 in the plates 218 of the track 5 and are secured in place with a
nut 232 for
purposes of securing the side piece 226 to the track 5.
[0133] As best shown in Fig. 34, dunnage 106 in the form of a plurality of
pouches 108
are suspended by and supported by a plurality of support member assemblies 66.
Each
pouch 108 has a front wall 109, a rear wall 111 and a bottom 113 extending
therebetween. As shown in Fig. 34, the top of the front wall 109 is attached
to one of
the support member assemblies 66 and the rear wall 111 being attached to an
adjacent
support member assembly 66 in any manner described or illustrated herein.
Although
the dunnage 106 shown comprises pouches, the dunnage may assume other shapes
or
configurations. Fig. 34 illustrates straps or space limiters 114 extending
between
adjacent pouch panels or walls to facilitate load or unloading products 40 as
described
herein. Fig. 34 illustrates products 40 being secured inside the pouches 108,
the
products 40 being purely for illustrative purposes, as described above. Any
embodiment
described or illustrated herein may be used with products of different sizes
or shapes.
The illustrated products 40 are not intended to be limited to any particular
size or shape
in any of the embodiments.
[0134] If desired, as shown in Fig. 29, each of the dunnage walls may have a
handle
234 sewn therein directly above each of the movable support member assemblies
66.
This feature may exist in any of the embodiments shown or described herein.
CA 02826768 2013-09-10
[0135] Figs. 37 and 38 illustrate an alternative embodiment of container 10j
very similar
to container 10i. For simplicity, like numbers represent like parts. Container
10j has an
outer frame 186j which is identical to outer frame 186 of the embodiment of
Figs. 29-36
except for the two front corner posts. As best shown in Fig. 37, each of the
two front
corner posts 190j of outer frame 186j of container 10j has slots 26a, 28a
identical to
those described and illustrated in door guides 210 of the container 101 for
purposes of
guiding movement of a door assembly like door assembly 34a. Therefore,
container 10j
lacks any door guides 210. In virtually all other respects, container 10j is
identical to
container 10i.
[0136] 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.
