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

Abstract

A method of unloading a container of products therein after shipment and being returned for reuse has a movable door assembly to ease the unloading 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 unloading products from a container, the method comprising:
 lowering an upper door segment of a door assembly such that pins of the upper door segment move in slots of the container to enable the upper door segment to be lowered in a controlled manner;   removing products supported by an upper layer of pouches, the pouches of the upper layer of pouches being supported by dunnage supports;   moving empty pouches of the upper layer away from the door assembly so they do not interfere with unloading a lower layer of products, the dunnage supports being guided by tracks on opposed sides of the container at the same level;   removing products supported by pouches of a lower layer of pouches, the pouches of the lower layer being supported by dunnage supports; and   raising the upper door segment of the door assembly to a raised and locked position.   
     
     
         2 . The method of  claim 1  wherein moving the empty pouches of the upper layer away from the door assembly comprises moving end members of the dunnage supports along the tracks. 
     
     
         3 . The method of  claim 1  wherein lowering the upper door segment comprises moving the upper door segment outside a stationary portion of the container. 
     
     
         4 . The method of  claim 1  wherein removing products supported by the upper layer of pouches comprises removing the products from the pouches one at a time, the pouch closest the door assembly being unloaded before the other pouches of the same layer. 
     
     
         5 . The method of  claim 1  wherein lowering the upper door segment comprises moving the upper door segment so the pins move through curved portions of upper slots of the container. 
     
     
         6 . The method of  claim 1  wherein removing products from pouches of the lower layer of pouches comprises removing product from each pouch beginning with the pouch of the lower layer of pouches closest to the door assembly. 
     
     
         7 . The method of  claim 1  wherein raising the upper door segment to a raised and locked position comprises moving the upper door segment so at least some pins of the upper door segment move through curved portions of some of the slots of the container. 
     
     
         8 . The container of  claim 1  wherein raising the upper door segment to a raised and locked position comprises moving the upper door segment so at least some pins of the upper door segment move through curved portions of upper slots of the container. 
     
     
         9 . A method of unloading products from a container loaded with products, 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;   removing products from an upper level of pouches;   moving empty pouches of the upper level away from the door assembly;   removing products from pouches of a lower level;   moving empty pouches of the lower level away 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 empty pouches of the lower level away from the door assembly comprises moving dunnage supports supporting the empty pouches of the lower 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 unloading 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;   removing products from top layer of pouches;   moving empty pouches of the upper layer away from the door assembly;   removing products from pouches of a lower layer;   moving empty pouches of the lower layer away from the door assembly;   removing products from pouches one layer at a time until all layers of pouches have been emptied; 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 layer.