Method of Loading Container Having Door Assembly and Multiple Layers of Dunnage

Abstract

A method of loading a container for holding product therein during shipment and being returned for reuse has a movable door assembly to ease the loading process. Layers of tracks are supported by opposite sides of the container. Movable dunnage supports extending between the tracks support dunnage such as pouches. The dunnage supports may include end members movable along the tracks.

What is claimed is: 
     
         1 . A method of loading a container with products for shipment, the method comprising:
 lowering a door assembly, the door assembly having pins movable in slots to enable the door assembly to be raised and lowered in a controlled manner;   moving a plurality of upper dunnage supports supporting an upper layer of pouches away from the door assembly,   moving a plurality of lower dunnage supports supporting a lower layer of pouches to a position near the door assembly,   inserting products into pouches of the lower layer of pouches;   moving the upper dunnage supports supporting the upper layer of pouches proximate the door assembly after the lower layer of pouches is loaded and inserting additional products into the pouches of the upper layer of pouches one pouch at a time and moving the loaded pouches of the upper layer of pouches away from the door assembly; and   raising the door assembly to a raised and locked position.   
     
     
         2 . The method of  claim 1  wherein inserting products into pouches of the lower layer of pouches comprises inserting at least one product into each pouch beginning with the pouch of the lower layer of pouches furthest from the door assembly. 
     
     
         3 . The method of  claim 1  wherein lowering the door assembly comprises moving a portion of the door assembly outside a stationary portion of the container. 
     
     
         4 . The method of  claim 1  wherein each of the dunnage supports comprises a pair of end members and a support extending between the end members, the end members moving in tracks at the same level. 
     
     
         5 . The method of  claim 1  wherein lowering the door assembly comprises moving the door assembly so the pins of the door assembly move through curved portions of the slots of the container. 
     
     
         6 . The method of  claim 1  wherein inserting products into pouches of the lower layer of pouches comprises inserting at least one product into each pouch beginning with the pouch of the lower layer of pouches furthest from the door assembly. 
     
     
         7 . The method of  claim 1  wherein raising the door assembly to a raised and locked position comprises moving the door assembly so at least some pins of the door assembly move through curved portions of some of the slots of the container. 
     
     
         8 . The container of  claim 1  wherein raising the movable door assembly to a raised and locked position comprises moving the door assembly so at least some pins of the door assembly move through curved portions of upper slots of the container. 
     
     
         9 . A method of loading a container with products for shipment, the method comprising:
 lowering a door assembly from a raised and locked position to a dropped position, the door assembly having portions movable in slots of the container;   moving a bottom level of pouches to a forward position near the lowered door assembly;   loading at least one product into a pouch of the bottom level furthest away from the door assembly;   moving the loaded pouch of the bottom level away from the door assembly;   repeating the loading process one pouch at a time until each pouch of the bottom level of pouches is full;   moving an empty upper level of pouches to a position near the lowered door assembly;   inserting products into pouches of the upper level of pouches, beginning with the pouch furthest from the lowered door assembly; and   raising the door assembly to its raised and locked position.   
     
     
         10 . The method of  claim 9  wherein moving the loaded pouch of the bottom level away from the door assembly comprises moving dunnage supports supporting the loaded pouch of the bottom level. 
     
     
         11 . The method of  claim 9  wherein lowering the door assembly comprises moving a portion of the door assembly outside a stationary portion of the container. 
     
     
         12 . The method of  claim 9  wherein lowering the door assembly comprises moving the door assembly so the portions of the door assembly move through curved portions of upper slots of the container. 
     
     
         13 . The method of  claim 9  wherein raising the door assembly to a raised and locked position comprises moving the door assembly so at least some pins of the door assembly move through curved portions of some of the slots of the container. 
     
     
         14 . The method of  claim 9  wherein moving the empty upper level of pouches to a position near the lowered door assembly comprises moving an upper level of dunnage supports from which the pouches hang. 
     
     
         15 . The method of  claim 9  wherein moving the empty upper level of pouches to a position near the lowered door assembly comprises moving an upper level of dunnage supports having end members movable in tracks at the same level. 
     
     
         16 . A method of loading a container with products for shipment, the method comprising:
 lowering a movable door assembly, the movable door assembly having pins movable in slots of the container to enable the door assembly to be raised and lowered in a controlled manner;   moving upper dunnage supports supporting an upper layer of pouches away from the door assembly,   moving lower dunnage supports supporting a lower layer of pouches to a position near the door assembly;   inserting products into pouches of the lower layer of pouches;   moving the upper dunnage supports supporting the upper layer of pouches proximate the door assembly after the lower layer of pouches is loaded and inserting additional products into the pouches of the upper layer of pouches and moving the loaded pouches of the upper layer of pouches away from the door assembly; and   raising the door assembly to a raised position.   
     
     
         17 . The method of  claim 16  wherein raising and lowering the movable door assembly comprises moving the pins through curved portions of upper slots of the container. 
     
     
         18 . The method of  claim 16  wherein raising and lowering the movable door assembly comprises moving the pins through curved portions of upper slots of the container and into linear portions of the upper slots. 
     
     
         19 . The method of  claim 16  wherein moving the upper dunnage supports comprises moving end members of upper dunnage supports along upper tracks. 
     
     
         20 . The method of  claim 16  wherein moving the upper dunnage supports comprises moving end members of upper dunnage supports along upper tracks secured to the container at the same level.