Interlocking crate and shipping container system

An apparatus comprising:

• interlocking bottom and side panels assembled into a shipping container, wherein the shipping container is self-supporting without mechanical fasteners;
• a plurality of shipping units disposed within the self-supporting shipping container and stacked substantially parallel to the bottom panel;
• a plurality of horizontally oriented slots formed in an opposing pair of the side panels, the slots arranged at different heights above the bottom panel;
• a cross member inserted within an opposing pair of the slots, the opposing pair of slots having a height selected to position the cross member for retaining the shipping units against vertical motion in a compressive loading arrangement;
• a top panel configured for interlocking with the plurality of side panels to cover the shipping container, wherein the top panel is spaced above the plurality of shipping units at a clearance maintained by the cross member;
• and
• a cross brace positioned between an opposing pair of the side panels at a top edge thereof, the cross brace configured to support the top panel against external loading.

A method comprising:

• assembling a plurality of interlocking side panels and an interlocking bottom panel to form a self-supporting shipping container;
• loading the self-supporting shipping container with a plurality of shipping units, the shipping units extending across the bottom panel in a substantially parallel orientation;
• inserting a cross piece into a pair of opposing horizontal slots formed in the side panels, the slots formed at a height selected to position the cross piece to restrain the shipping units against vertical motion in a compressive loading arrangement;
• inserting a cross brace between an opposing pair of the side panels, the cross brace positioned along a top edge thereof;
• and
• closing the shipping container with an interlocking top panel, wherein the top panel is spaced above the shipping units with a clearance maintained by the cross piece, such that the cross brace isolates the shipping units from compressive loading on the top panel by transferring the compressive loading to the side panels.