Storage container, system comprising one or more such storage containers, and method of assembling the storage container

Abstract

A storage container for an automated storage and retrieval system, ASRS, configured to be stacked in a stack of storage containers in which a lower storage container supports one or more storage containers positioned above, the storage container being adapted to be lifted by a clamp on a lifting device so that the storage container can be lifted from above, wherein the storage container comprises a bottom, four side portions each hingedly connected to an edge of the bottom, four corner posts each configured to interconnect a pair of side portions to each other in a horizontal direction when the pair of side portions are positioned at substantially 90 degrees with respect to the bottom (10) and with respect to each other. Also described is an automated storage and retrieval system comprising a two-dimensional rail system and one or more storage containers. Also described are methods of transporting and assembling storage containers.

Description

Technical Field

[0001] This invention relates to an automated storage and retrieval system for storing and retrieving containers, and more particularly to a fire-resistant storage container, a system comprising one or more of the storage containers, and a method for assembling the storage containers. The storage container is particularly suitable for use in an automated storage and retrieval system (ASRS) in which storage containers are stacked one on top of another to form a stack, and in which the storage containers can be retrieved by a container handling vehicle or robot operating on a track system extending along a first direction X and a perpendicular second direction Y. Background Technology

[0002] FIG. 1 A typical prior art automated storage and retrieval system 1 with a frame structure 100 is disclosed, and FIG. 2 and FIG. 3 Two different prior art container handling vehicles, 201 and 301, suitable for operation on such system 1 are disclosed.

[0003] The frame structure 100 includes upright members 102, horizontal members 103, and storage volumes comprising storage columns 105 arranged in rows between the upright members 102 and the horizontal members 103. In these storage columns 105, storage containers 106 (also referred to as boxes) are stacked one on top of another to form a stack 107. Members 102 and 103 can typically be made of metal, such as extruded aluminum profiles.

[0004] The frame structure 100 of the automated storage and retrieval system 1 includes a track system 108 arranged across the top of the frame structure 100. Multiple container handling vehicles 201, 301 operate on the track system 108 to raise and lower storage containers 106 from storage columns 105 into the columns, and also to transport storage containers 106 above the storage columns 105. The track system 108 includes: a first set of parallel tracks 110 arranged to guide the container handling vehicles 201, 301 along a first direction X across the top of the frame structure 100; and a second set of parallel tracks 111 arranged perpendicular to the first set of tracks 110 to guide the container handling vehicles 201, 301 in a second direction Y perpendicular to the first direction X. Containers 106 stored in the columns 105 are accessed by the container handling vehicles through access openings 112 in the track system 108. Container handling vehicles 201 and 301 can move laterally above storage column 105, that is, in a plane parallel to the horizontal XY plane.

[0005] The upright members 102 of the framework structure 100 can be used for guiding the storage containers during lifting of the containers from and lowering of the containers into the columns 105. The stacks 107 of containers 106 are typically self-supporting.

[0006] Each prior art container handling vehicle 201, 301 comprises a vehicle body 201a, 301a and a first set of wheels and a second set of wheels 201b, 301b, 201c, 301c which enable the container handling vehicle 201, 301 to move laterally in the X and Y directions, respectively. In FIGS. 2-3 In the example prior art disclosed in

[0007] Each prior art container handling vehicle 201, 301 further comprises lifting devices (not shown) for vertical transportation of storage containers 106, e.g. lifting a storage container 106 from a storage column 105 and lowering a storage container 106 into a storage column. The lifting devices comprise one or more gripping / engaging devices adapted to engage a storage container 106 and which can be lowered from the vehicle 201, 301 so that the position of the gripping / engaging devices relative to the vehicle 201, 301 can be adjusted in a third direction Z which is orthogonal to the first and second directions X and Y. Some parts of the gripping devices of the container handling vehicle 301 are shown in FIG. 3 with reference 304. The gripping devices of the container handling device 201 are located within the vehicle body 201a in FIG. 2

[0008] Conventionally, and also for the purposes of the present application, Z=1 identifies the uppermost level of storage containers, i.e. the level directly below the rail system 108, Z=2 identifies the second level below the rail system 108, Z=3 the third level, etc. In FIG. 1 In the example prior art disclosed in FIG. 1 FIG. 1 ​​A storage container identified as 106’ can be said to occupy storage position X = 10, Y = 2, Z = 3. The container handling vehicles 201, 301 can be said to travel in level Z = 0, and each storage column 105 can be identified by its X and Y coordinates.

[0009] The storage volume of the framework structure 100 is often referred to as the grid 104, where the possible storage locations within this grid are referred to as storage cells. Each storage column can be identified by a position in the X and Y directions, while each storage cell can be identified by a container designation in the X, Y and Z directions.

[0010] Each prior art container handling vehicle 201, 301 comprises a storage compartment or space for receiving and stowing a storage container 106 when transporting the storage container 106 across the rail system 108. The storage space can comprise a cavity arranged centrally within the vehicle body 201a, as shown in FIG. 2 WO 2015 / 193278 A1, the content of which is incorporated herein by reference.

[0011] FIG. 3 An alternative configuration of a container handling vehicle 301 having a cantilever structure is shown. Such vehicles are described in detail in, for example, NO 317 366, the content of which is also incorporated herein by reference.

[0012] FIG. 2 The central cavity type container handling vehicle 201 shown in

[0013] Alternatively, the footprint of the central cavity type container handling vehicle can be larger than the lateral area defined by the storage columns 105, as disclosed in WO 2014 / 090684 A1.

[0014] The rail system 108 typically comprises rails with grooves in which the wheels of the vehicles run. Alternatively, the rails can comprise upwardly projecting elements of which the wheels of the vehicles comprise a flange to prevent derailing. These grooves and upwardly projecting elements are collectively referred to as tracks. Each rail can comprise one track, or each rail can comprise two parallel tracks.

[0015] WO 2018 / 146304, the content of which is incorporated herein by reference, shows a typical configuration of a rail system 108 comprising rails and parallel tracks in both the X and Y directions.

[0016] In the framework structure 100, the majority of the columns 105 are storage columns 105, i.e. columns 105 where storage containers 106 are stored in stacks 107. However, some columns 105 can have other purposes. In FIG. 1 the columns 119 and 120 are such dedicated columns from which storage containers 106 are unloaded and / or picked by the use of the container- handling vehicles 201, 301 so that they can be transported to an access station (not shown) where the storage containers 106 can be accessed from outside the framework structure 100, or brought out of or into the framework structure 100. Such locations are typically referred to within the art as "ports", and the columns in which the ports are located can be referred to as "port columns" 119, 120. The transport to the access station can be in any direction, i.e. horizontally, inclined and / or vertically. For example, a storage container 106 can be placed in a random or dedicated column 105 within the framework structure 100, then picked by any container-handling vehicle and transported to a port column 119, 120 for further transport to an access station. It is noted that the term "inclined" denotes transport of a storage container 106 with a general transport orientation that is somewhere between horizontal and vertical.

[0017] In FIG. 1 the first port column 119 can for example be a dedicated drop-off port column, where the container-handling vehicles 201, 301 can drop off transported storage containers 106 to the access station or a transfer station, and the second port column 120 can be a dedicated pick-up port column, where the container-handling vehicles 201, 301 can pick up storage containers 106 that have been transported from the access station or a transfer station.

[0018] The access station can typically be a picking or a replenishment station where product items are removed from or positioned into the storage containers 106. In a picking or replenishment station, the storage containers 106 are typically not removed from the automated storage and retrieval system 1, but rather returned into the framework structure 100 after access. The ports can also be used for transferring storage containers to another storage facility, e.g. to another framework structure or to another automated storage and retrieval system, to a transport vehicle, such as a train or a lorry, or to a production facility.

[0019] A conveyor system, including conveyors, is typically employed for transporting the storage containers between the port columns 119, 120 and the access station.

[0020] If the port columns 119, 120 and the access station are located at different levels, the conveyor system can include lifting devices with vertical components for transporting the storage containers 106 vertically between the port columns 119, 120 and the access station.

[0021] The transport system can be arranged to transfer storage container 106 between different frame structures, such as those described in WO2014 / 075937A1, the contents of which are incorporated herein by reference.

[0022] When you need to access the stored FIG. 1 When a storage container 106 is located in a column 105 as disclosed, a container handling vehicle 201, 301 is instructed to remove the target storage container 106 from its position and transport the storage container to the unloading port column 119. This operation involves moving the container handling vehicle 201, 301 to a position above the storage column 105 where the target storage container 106 is located, removing the storage container 106 from the storage column 105 using the lifting device (not shown) of the container handling vehicle 201, 301, and transporting the storage container 106 to the unloading port column 119. If the target storage container 106 is located deep within the stack 107, i.e., one or more other storage containers 106 are positioned above the target storage container 106, the operation also involves temporarily moving the storage container positioned above before lifting the target storage container 106 from the storage column 105. This step, sometimes referred to in the art as “digging,” can be performed using the same container handling vehicle subsequently used to transport the target storage container to the unloading port column 119, or using one or more other cooperating container handling vehicles. Alternatively or additionally, the automated storage and retrieval system 1 may have container handling vehicles 201, 301 specifically designed for the task of temporarily removing storage containers 106 from storage columns 105. Once the target storage container 106 has been removed from the storage column 105, the temporarily removed storage container 106 can be repositioned back into the original storage column 105. However, alternatively, the removed storage container 106 can be repositioned to another storage column 105.

[0023] When storage container 106 is to be stored in a column 105, a container handling vehicle 201, 301 is instructed to pick up storage container 106 from pick-up port column 120 and transport the storage container to a position above the storage column 105 to which it is to be stored. After any storage container 106 positioned at or above the target location within stack 107 has been removed, the container handling vehicle 201, 301 positions the storage container 106 at the desired location. The removed storage container 106 can then be lowered back into storage column 105 or repositioned to another storage column 105.

[0024] For monitoring and controlling the automated storage and retrieval system 1, e.g. monitoring and controlling the positions of the respective storage containers 106 within the framework structure 100, the contents of each storage container 106 and the movement of the container handling vehicles 201, 301 so that a desired storage container 106 can be delivered to the desired position at the desired time without the container handling vehicles 201, 301 colliding with each other, the automated storage and retrieval system 1 comprises a control system 500, which is typically computerised and which typically comprises a database for keeping track of the storage containers 106.

[0025] Typically, a building or site where an ASRS is installed is equipped with a water sprinkler system to cope with the situation where a fire occurs. Such a water sprinkler system is typically installed on the roof and is a high investment cost. In particular, in smaller ASRS, such as in a micro-fulfillment system having a limited number of storage containers or bins and a limited number of container handling vehicles, the regulatory requirement for a fire to be supervised by an expensive water sprinkler system can constitute a significant part of the investment cost of the entire ASRS. In some cases, the cost of a water sprinkler system can result in a planned ASRS not being installed.

[0026] It is an object of the present invention to be able to store containers for delivery to a micro-fulfillment ASRS installation. SUMMARY

[0027] The present invention is set forth and characterized in the independent claims, while the dependent claims describe further features of the invention.

[0028] The present invention relates to a storage container. The storage container is preferably of the same size and can be operated by a container handling vehicle mentioned in the “background art”.

[0029] A storage container for an automated storage and retrieval system (ASRS) is disclosed, the storage container being configured to be stacked in a stack of storage containers in which a lower storage container supports one or more storage containers positioned above, the storage container being adapted to be lifted by a clamp on a lifting device so that the storage container can be lifted from above, wherein the storage container comprises:

[0030] a bottom part;

[0031] four side parts, each side part being hingedly connected to an edge of the bottom part;

[0032] four corner posts, each corner post being configured to interconnect a pair of adjacent side parts to each other in a horizontal direction when the pair of side parts is positioned at substantially 90 degrees with respect to the bottom part and with respect to each other.

[0033] This means that two adjacent sides are locked to each other and that these two adjacent sides are prevented from moving in a horizontal direction relative to each other when the bottom of the storage container is supported on a surface, i.e. during normal use of the storage container.

[0034] The bottom is preferably rectangular or square in shape.

[0035] The fact that each of the four sides is hingedly connected to the edge of the bottom means that the sides are connected by a continuation of the bottom material. The five sides of the container can be provided by a connecting area in which the hinged connection can be formed by one sheet material with a line of weakness along which the sides are folded, or can be formed as separate sheet materials adjoining along the edges of the bottom, etc.

[0036] Having four corner posts, each configured to interconnect a pair of adjacent sides to each other in a horizontal direction when the pair of sides is positioned at approximately 90 degrees relative to the bottom and to each other, this feature should be understood as 90 degrees + / - 5 degrees.

[0037] In a preferred embodiment, the corner posts are structural posts in the sense that they are configured to support all storage containers positioned thereabove. In other words, the corner posts take the weight of all or most of the storage containers positioned thereabove. This can be achieved by manufacturing the corner posts in a relatively rigid material with high strength and configuring them such that they, rather than the sides, take the vertical load from the storage containers located above. The configuration of the corner posts and the engagement of the sides with the posts can be designed to lock the sides in their approximately 90 degree position when assembling the storage container, thereby stabilizing the structure of the storage container. In this way, the sides only need to be designed with a limited vertical strength, sufficient to carry the load of the storage container and any items therein, i.e. a maximum in the range of 30-40 kg.

[0038] The storage container can comprise lifting holes along its upper edge, arranged in appropriate positions complementary to the clamp positions of the lifting device and having dimensions complementary to the dimensions of the lifting device, so that the storage container can be lifted by the clamps of the lifting device.

[0039] In order for the lowermost storage container in a stack of storage containers to be able to support, for example, 15 boxes, each of a maximum of 30 kg, the corner posts should be designed so that each corner post takes at least 150 kg (assuming a safety margin of 150 kg (4 x 150 kg = 600 kg, while the maximum weight of the stack is 15 boxes x 30 kg = 450 kg).

[0040] By designing the corner posts to take all or most of the vertical load from the storage container above, the dimensions of the sheet material of one storage container need not be designed to take more load than the weight of the storage container plus any contents therein (e.g. up to 30kg). Instead of transferring the vertical load from the storage container above, the sheet material can act under tension to stabilise the position of the corner posts so that the corner posts can provide the main load path for the vertical load.

[0041] The bottom and sides of the storage container can comprise sheet material which can be provided as a blank from which the bottom and four sides are made, wherein each side can be connected to a respective edge of the bottom by a living hinge provided by a line of weakness which extends between each side and the bottom so that the respective side can be folded relative to the bottom along the line of weakness. In this way, the bottom and sides can be made from the same material.

[0042] This can enable pre-manufacture of the sheet material and transport of a plurality of storage containers stacked inside one another to significantly reduce the amount of transport required. Furthermore, the height of the box can be easily changed by simply changing the dimensions of the sides of the sheet material.

[0043] The sheet material can be manufactured using known techniques. For example, the sheet material can be punched or stamped.

[0044] To increase the strength of the sides, the sheet material can be provided with recesses which extend in the vertical direction (when the sides are folded upwards). The recesses are shaped into the sheet material (not through holes). Similarly, the bottom can be provided with recesses. Alternatively, other means of increasing strength can be employed, such as increasing the thickness of the sides and / or the bottom, fitting separate reinforcing pieces to the sides and / or the bottom, etc.

[0045] A living hinge is a thin flexible hinge (flexural bearing) made of the same material as the two rigid pieces to which it is connected. The living hinge is typically thinned or cut to allow the rigid pieces to bend along the line of the hinge.

[0046] The line of weakness can be a line of reduced material quantity of the sheet material. The reduction in material can be achieved by thinning or by providing a hole, or by both.

[0047] The relatively thin portion of the sheet material along the line of weakness forms a relatively weak area in the sheet material and ensures that a bend or fold is formed along the desired line of the sheet material. Thus, the line of weakness is the fold edge of the bottom.

[0048] The line of weakness can comprise a through hole. The through hole can achieve a relatively weak area or line in the sheet material and ensures that a bend is formed along the desired line of the sheet material.

[0049] The through hole can occupy more than 30% of the line of weakness. Alternatively, the through hole can occupy more than 30% or less than 30% of the line of weakness, such as more than 20% and 40% of the line of weakness.

[0050] In an aspect, the cross-sectional area of the through hole can have a size sufficient for water to flow through. The through hole can be formed as a slot, aperture, or recess, sized sufficient for water to drain through by natural flow.

[0051] In an aspect, the through hole comprises:

[0052] - an inlet arranged on an inner surface of the storage container; and

[0053] - an outlet arranged on an outer surface of the storage container. The inlet can be arranged at a height equal to or higher than the outlet of the through hole. This configuration ensures that the centerline of the through hole can extend horizontally or downward from the interior to the exterior of the storage container. That is, the centerline of the through hole can be a drop line that extends outward from the line of weakness when the storage container is assembled.

[0054] As shown above, the through hole can be arranged along the line of weakness. Alternatively or in addition, the through hole can be formed in the bottom proximate or close to the line of weakness. Arranging the through hole at these locations can also ensure that the water flowing through enters the lower layer of storage containers in the stack. In order for the majority of the water to flow to the lower layer of storage containers, and because the storage containers are stacked one on top of another (rather than partially into each other), with at least the corner posts of the stacked storage containers supporting one another, the centerline of the through hole should preferably form a negative angle with respect to the horizontal plane. For example, with the bottom in a horizontal plane, the centerline of the through hole forms a negative angle with respect to the bottom.

[0055] The line of weakness can be a straight line. This ensures that the fold is formed along a straight line. The straight line or straight lines ensure that the sides are bent along the desired lines so that the final storage container meets the requirements in terms of form and shape, among others. On site, it is preferable to test all storage containers to determine potential damage during transport, which is a standard procedure today after transporting the plastic containers after casting. Irregular storage containers will not fit into the storage column or stack of storage containers and / or can get stuck in the column and / or the clamps of the lifting device can have difficulty clamping the storage containers.

[0056] The sheet material can be punched to provide the profile of the bottom and four sides. The line of weakness can be formed at the same time. The sides and bottom of the storage container can be shaped to increase strength.

[0057] The bottom and sides can be made of a metal sheet material, a plastic sheet material, a paperboard sheet material, a composite sheet material, or other suitable material.

[0058] The bottom and sides can be made of aluminum or steel.

[0059] In a preferred embodiment, the storage containers are manufactured using fire resistant materials such as metal or fire resistant plastic to avoid the use of expensive water sprinkler systems in the micro-fulfillment ASRS installation.

[0060] The upper end of the corner post can be at the same level as or higher than the top edge of the side. Similarly, the lower end of the corner post can be at the same level as or lower than the lower end of the side. This arrangement ensures that the upper end of the corner post is in contact with the underside of the corner post of the storage container above, which again ensures that the full or majority of the vertical load of the storage container above is supported by the corner post.

[0061] The corner post can be made of a plastic material. For example, the corner post can be molded and can include a profile configured to engage with the side of the storage container.

[0062] The storage container according to any of the preceding claims, wherein the corner post comprises a longitudinal notch on the outer surface. This longitudinal or vertical notch helps enable the storage container to be lifted by a clamp on a lifting device, as the box guide of the lifting device can be guided along the notch on different corner posts.

[0063] The corner post can also have a shape and material that simplifies the guiding along the upright members of the frame. As the upright members are typically made of aluminum, at least the surface of the corner post that is in contact with the upright member should be made of a different material than aluminum to prevent scratching. However, in the case that the corner post is made of aluminum, the surface in contact with the upright member can be coated or otherwise treated with a different material than aluminum.

[0064] Each side can comprise a top edge and two opposite side edges, and each side can be folded to form a fold at the side edges, thereby providing an outwardly extending rib at each side edge, and each corner post can comprise a pair of grooves extending in its longitudinal direction for receiving respective outwardly extending ribs from a pair of adjacent sides. This locks the two adjacent side panels relative to each other in a rectangular manner (i.e. perpendicularly).

[0065] The crease in the sheet material should locally stiffen the area to provide additional strength - and the fold provides a flange (or it can form another shape such as a crimp) that extends at an angle to the plane of the side (ideally perpendicular, but other angles are also very effective). This forms a shaped part (corner, rib, flange, plug or crimp - in the case of a crimped edge etc.) that then locks in the longitudinal (i.e. vertical) groove of the corner post when slid in to engage, in this way being able to resist any tension or hoop forces in the container that would force the sides apart.

[0066] The distance between the two side edges of a side section can be shorter than the distance between the two bottom edges. Thus, the adjacent side edges of adjacent sides may not be sufficient to form the true geometric angles inside the storage container. Corner posts can be fixed to these edges and provide structural bridges for the transfer of circumferential forces from one side section to another. Furthermore, the corner posts fix the sides in a spaced-apart configuration.

[0067] The top edge may form part of the flange portion of the side, and the corner post may include a snap-lock connection for locking the corner post to the flange portion.

[0068] The flange portion may include a main portion, a middle portion and an outer portion, and the top edge may form the upper end of the outer portion.

[0069] The middle section can fold outwards relative to the main section, and the outer section folds upwards relative to the middle section, thus misaligning the outer section with respect to the main section. This construction strengthens the sides, as they are hardened through the flange portions. This reduces the risk of the storage container bending.

[0070] The main part and the outer part are preferably substantially parallel.

[0071] The cross-sectional area formed by the outer portion of the side can be larger than the bottom in all directions, and therefore, the through-hole at the bottom of the storage container supported directly above ensures that all water flowing through the through-hole into the storage container above is guided into the storage container via the outer, middle, and main portions of the flange portion. In other words, the outer portion of the flange portion located at the top of the side extends outward to guide water flowing out of the through-hole, which forms a weak line in the upper storage container. That is, the through-hole functions both to form a weak line and to guide water downward through to the lower storage container in the event of a fire. Thus, the outer portion of the side can be arranged in all horizontal directions to exceed any through-hole in the storage container supported directly above.

[0072] The length of the side portions in the X- and Y-directions is preferably longer than the distance between the two upright members in the X- and Y-directions. This makes the position of the side edges of the side portions of the storage container relative to the upright members of the frame of the ASRS such that in case the corner posts melt during a fire and one or more of the four side portions move outwards as they are no longer supported by the corner posts, the side portions will rest against the upright members. This will maintain the integrity and stability of a large part of the stack of storage containers and prevent the stack from collapsing. This can be especially important in case the storage containers used in the ASRS have a bottom and side portions made of a fireproof material, such as metal, and the corner posts are made of a non-fireproof material, such as plastic. The combination of the side portions made of metal, such as aluminium or steel, with water can be especially advantageous as aluminium is a good heat conductor and water has a high specific heat capacity, so together they can absorb a lot of heat from the area of the fire to help prevent the spread of the fire. Thus, the combination of aluminium and water can provide more benefits than not burning, at least at relatively low fire temperatures where aluminium does not burn.

[0073] In an embodiment, the storage container 106 can further comprise a closure locking frame for locking all of the top edges of the side portions and the corner posts relative to each other when the top edges are folded to form the folded portions.

[0074] The top edges and the corner posts can comprise open upwardly directed recesses and the locking frame can comprise complementary downwardly directed protrusions for locking with the recesses. The locking between the recesses and the protrusions can be achieved by a snap-lock connection.

[0075] In an alternative embodiment, the top edges can be folded and the storage container can further comprise a closure locking frame for locking all of the top edges of the side portions and the corner posts relative to each other. In this embodiment, the closure locking frame comprises open upwardly directed recesses.

[0076] Also disclosed is an automated storage and retrieval system (ASRS) comprising a two-dimensional rail system comprising a first set of parallel rails arranged to guide container handling vehicles to move in a first direction X on top of a framework structure and a second set of parallel rails arranged perpendicular to the first set of rails to guide the container handling vehicles to move in a second direction Y perpendicular to the first direction X, wherein a plurality of container handling vehicles are operating on the rail system and wherein the system comprises one or more storage containers as defined above.

[0077] Also disclosed is a method of transporting a storage container and assembling the storage container on site, wherein the storage container comprises:

[0078] a bottom portion;

[0079] four side portions, each side portion being hingedly connected to an edge of the bottom portion;

[0080] four corner posts, each corner post configured to interconnect a pair of adjacent side portions to each other in a horizontal direction when the pair of side portions are positioned at approximately 90 degrees relative to the base and to each other; and wherein the method comprises the steps of:

[0081] - folding each side portion to an angle of between 20 and 85 degrees relative to the base;

[0082] - stacking the partially folded side portions and the base at least partially into or within each other on a common transport platform;

[0083] - placing the corner posts on the platform;

[0084] - transporting the stack of partially folded side portions and the base and the corner posts to the site of the ASRS;

[0085] - assembling the storage container at the site.

[0086] The bringing of the material sheets into or within each other enables the transport of the storage container as a semi-finished product, so that final assembly can be performed at the site of the ASRS, with a reduction of the transport volume required for transporting the storage container by a factor of three compared to prior art solutions in which the storage container is cast as one piece and stacked one on top of the other from the factory to the ASRS installation site.

[0087] The assembling of the storage container at the site can be performed by a human operator or a robotic operator.

[0088] The transport platform can be a standardized pallet, such as a Euro pallet.

[0089] In an aspect of the method, each side portion can comprise a top edge and two opposite side edges, and each side portion can be folded to form a fold at the side edges, thereby providing an outwardly extending rib at each side edge, and each corner post can comprise a pair of grooves extending along a longitudinal direction thereof for receiving respective outwardly extending ribs of a pair of adjacent side portions, and the step of assembling the storage container at the site can comprise:

[0090] - folding the side portions fully so that each side portion extends at 90 degrees from the base;

[0091] - sliding each corner post in from above into locking engagement with the edges of a pair of adjacent side portions.

[0092] The top edge can form part of a flange portion of the side portion, and the corner post can comprise a snap-lock connection for locking the corner post to the flange portion, and the method can further comprise:

[0093] - locking the corner post to the flange portion of the storage container to lock the corner post in locking engagement with the edges of the adjacent side portions.

[0094] In an aspect, when the top edges are folded, and the storage container further comprises a closure locking frame for locking all the top edges of the side portions and the corner posts relative to each other, the method can comprise the steps of:

[0095] - locking the locking frame to the side portions and the corner posts.

[0096] The top edges and the corner posts can comprise upwardly oriented recesses, and the locking frame can comprise complementary downwardly oriented protrusions for locking with the recesses, and the method can comprise:

[0097] - locking the locking frame to the side portions and the corner posts via the recesses and the protrusions.

[0098] A method of assembling a storage container as defined above on site in an ASRS is also disclosed, wherein the method comprises the steps of:

[0099] - folding each side portion completely so that each side portion extends at 90 degrees from the bottom portion;

[0100] - sliding each corner post in from above to lockingly engage with the edges of a pair of adjacent side portions;

[0101] - locking the corner post to the flange portion of the storage container to lock the corner post in locking engagement with the edges of the adjacent side portions.

[0102] The snap locking of the corner posts can be achieved using snap locking portions that snap the corner posts to the flange portion of the storage container.

[0103] Although the present invention has been described in relation to a storage container in an ASRS, it is also applicable to similar systems such as vertical farming, micro-fulfillment or grocery stores.

[0104] The related terms “upper”, “lower”, “under”, “over”, “above”, “inner”, “outer” and the like are to be understood in their general meaning as well as shown in a Cartesian coordinate system. BRIEF DESCRIPTION OF DRAWINGS

[0105] The following drawings are appended in order to facilitate the understanding of the present invention. These drawings show embodiments of the present invention, which will now be described by way of example only, in the drawings:

[0106] FIG. 1 is a perspective view of a frame structure of a prior art automated storage and retrieval system.

[0107] FIG. 2is a perspective view of a prior art container handling vehicle having a centrally arranged cavity for carrying storage containers therein.

[0108] FIG. 3 is a perspective view of a prior art container handling vehicle having a cantilever for carrying storage containers thereunder.

[0109] FIG. 4A is a top perspective view of a storage container according to a first embodiment of the application;

[0110] FIG. 4B is FIG. 4A is a top enlarged view of section A in

[0111] FIG. 4C is a perspective view from below of FIG. 4A

[0112] FIG. 4D is a side view of the relatively long side (i.e. X-direction) of the storage container according to the first embodiment;

[0113] FIG. 4E is a side view of the relatively short side (i.e. Y-direction) of the storage container according to the first embodiment;

[0114] FIG. 4F is a top view of the storage container according to the first embodiment;

[0115] FIG. 4G is a top view of the sheet material forming the bottom and the four sides of the storage container according to the first embodiment;

[0116] FIG. 4H is FIG. 4G is a side perspective view of the sheet material in

[0117] FIG. 4I is FIG. 4G and FIG. 4H is a side perspective view of the sheet material in

[0118] FIG. 5A , FIG. 5B and FIG. 5C are detailed views of a corner post of the first embodiment of the storage container, wherein FIG. 5A is a side perspective view of the corner post, FIG. 5B is a top view of the corner post, and FIG. 5C is a side view of the corner post;

[0119] FIG. 6 ​is an exploded view of the corner posts and the side portions of the storage container according to the first embodiment;

[0120] FIG. 7A shows a stack of storage containers assembled according to the first embodiment;

[0121] FIG. 7B is a detailed view of section G in FIG. 7B showing details of the relative position of the through-going hole in the upper storage container relative to the outer portion of the flange portion of the lower storage container;

[0122] FIG. 7C is a simplified view of FIG. 7B showing the storage containers located relatively upper, showing the centre line of the through-going hole in the upper storage container;

[0123] FIG. 7B is a simplified view of FIG. 7C where some details of the upper storage container and the lower storage container 106 have been omitted to better illustrate the principle of how water will flow from a storage container located relatively upper to a storage container located relatively lower;

[0124] FIG. 7B is a perspective view of a stack of storage containers according to the first embodiment, and shows the gap formed between the side portions of two adjacent storage containers (i.e. a gap is formed between the side portions of two storage containers, one of which is stacked directly above the other);

[0125] FIG. 7C is a top view showing the position of the side edges of the side portions relative to the upright members of the frame structure;

[0126] FIG. 8A is a view similar to FIG. 8B where the corner posts have been removed;

[0127] FIG. 8A is an exploded view of a storage container according to the first embodiment, the storage container further comprising dividers dividing the inventory of the storage container into separate sections;

[0128] FIG. 9A is a detailed view of section L in FIG. 9B ;

[0129] FIG. 9A shows a pallet with two stacks of sheet material having the side portions folded for transport;

[0130] FIG. 10 is a perspective view of a storage container according to the second embodiment;

[0131] FIG. 11A is a side view of a long side of a storage container according to the second embodiment;

[0132] FIG. 11B is a side view of a short side of a storage container according to the second embodiment;

[0133] FIG. 11C is a top view of a storage container according to the second embodiment;

[0134] FIG. 11D is a bottom view of a storage container according to the second embodiment;

[0135] FIG. 11E is a detailed view of section C in FIG. 11F

[0136] FIG. 11E is a view along line D-D in FIG. 11G

[0137] FIG. 11B is a top view of the sheet material forming the bottom and four sides of a storage container according to the second embodiment;

[0138] FIG. 12A is a side perspective view of the sheet material in FIG. 12B

[0139] FIG. 12A is an exploded view of a corner post, a side and a locking frame of a storage container according to the second embodiment;

[0140] FIG. 12C shows a pallet with two stacks of sheet material with partially folded sides for transport and another pallet with stacked locking frames;

[0141] FIG. 13A is a view from a short side of the pallet with stacked locking frames in FIG. 13B

[0142] is a top view of the pallet with stacked locking frames in FIG. 13A FIG. 13C and FIG. 13A

[0143] FIG. 13B is a view from a short side of the pallet with stacked sheet material with partially folded sides in FIG. 13D

[0144] FIG. 13A is a top view of the pallet with stacked sheet material with partially folded sides in FIG. 13E and FIG. 13A ​​​​​​a top view of a tray with a sheet material folded with stacked side portions in the tray. DETAILED DESCRIPTION

[0145] In the following, embodiments of the present application will be discussed in more detail with reference to the accompanying drawings. It should be understood, however, that the drawings solely are intended for purposes of illustration only and are not intended to limit the scope of the subject matter in any way.

[0146] The framework structure 100 of the automated storage and retrieval system 1 is constructed according to the prior art framework structure 100 described above in connection with FIG. 13D i.e. a plurality of upright members 102 and a plurality of horizontal members 103, which are supported by the upright members 102, and the framework structure 100 further comprises a first upper rail system 108 in the X- and Y-directions.

[0147] The framework structure 100 further comprises storage compartments in the form of storage columns 105 arranged between the members 102, 103, wherein storage containers 106 can be stacked within the storage columns 105 in the form of stacks 107.

[0148] The framework structure 100 can have any size. In particular, it should be understood that the framework structure can be wider and / or longer and / or deeper than the framework structures disclosed in FIGS. 1-3 WO 2015 / 015405 A1. For example, the horizontal extent of the framework structure 100 can be larger than 700 x 700 columns and its storage depth is larger than 12 containers.

[0149] First embodiment of a storage container

[0150] A first embodiment of an automated storage and retrieval system according to the present application will now be discussed in more detail with reference to Figs. 4 to FIG. 1

[0151] FIG. 10 is a top perspective view of a storage container 106 according to the first embodiment of the present application. The storage container 106 is constructed for use in an automated storage and retrieval system (ASRS) 1 (see FIG. 4A ) as described above in connection with FIG. 1 and is lifted by a container handling vehicle 201, 301 as described above in connection with FIG. 1 and FIG. 2 Other forms of container handling vehicles 201, 301 can also be used. The storage container 106 is further constructed for being stacked in the form of stacks 107 (see FIG. 3 ) of storage containers 106, wherein a lower storage container 106 supports one or more storage containers 106 positioned above. The storage container 106 is further adapted to be engaged by a clamp 304 (see FIG. 1 ​) is lifted so that the storage container 106 can be lifted from above. The disclosed storage container 106 has a rectangular base 10 and four side portions 11', 11", 11"', 11"". Each side portion 11', 11", 11"', 11"" is hingedly connected to a respective edge 14', 14", 14"', 14"" of the base 10. Four corner posts 12', 12", 12"', 12"" are also disclosed. Each corner post 12', 12", 12"', 12"" is configured to interconnect a pair of adjacent side portions 11', 11", 11"', 11"" to each other in a horizontal direction when the pair of side portions 11', 11", 11"', 11"" are positioned at approximately 90 degrees relative to the base 10 and to each other (i.e. as shown in FIG. 3 Figure 1). The first short side portion 11' (i.e. the "first side portion") is connected to the first long side portion 11" (i.e. the "second side portion") via the first corner post 12'. The first long side portion 11" (i.e. the "second side portion") is further connected to the second short side portion 11"' (i.e. the "third side portion") via the second corner post 12". The second short side portion 11"' (i.e. the "third side portion") is connected to the second long side portion 11"" (i.e. the "fourth side portion") via the third corner post 12"'. The second long side portion 11"" (i.e. the "fourth side portion") is connected to the first short side portion 11' (i.e. the "first side portion") via the fourth corner post 12"".

[0152] FIG. 4A is FIG. 4B Figure 1. Section A is a detailed view of the intersection between the third side portion 11"' and the fourth side portion 11"". The disclosed first side portion 11' and fourth side portion 11"" both include a top edge 18 and two opposing side edges (only one side edge of each side portion is disclosed). The first and fourth side portions 11', 11"" are folded to form a fold 20 at the side edges, thereby providing an outwardly extending rib 19 at each side edge. The disclosed corner post 12"" has a pair of grooves 21 extending along its longitudinal direction, each groove for receiving one of the respective outwardly extending ribs 19 from the first and fourth side portions 11', 11"".

[0153] The locking frame 70 is connected to the top edges 18 of the side portions 11' - 11"".

[0154] The disclosed side portions 11'-11'''' and bottom portion 10 have recesses 40 to increase strength. The disclosed side portions 11'-11'''' have recesses extending vertically (when the side portions 11'-11'''' are folded upwards). The recesses are shaped (i.e., not through holes). Similarly, the disclosed bottom portion 10 has a recess extending from the second side portion 11'' toward the fourth side portion 11'''' (i.e., extending between the first long side portion and the second long side portions 11'', 11'''' of the bottom portion 10).

[0155] like FIG. 4A As can be seen, the disclosed fourth corner post 12'''' has a longitudinal notch 17 on its outer surface. This longitudinal or vertical notch 17 facilitates the passage of the storage container 106 through the clamp 304 on the lifting device (see...). FIG. 4B The lifting device is lifted because the box guide (not shown) of the lifting device can be guided along the notches 17 on the different corner posts 12', 12'', 12''', 12''''.

[0156] The disclosed corner post 12'''' also has an outer surface 42 for connection with the upright members 102 of the frame structure 100 (see FIG. 3 Sliding contact. If the upright member 102 is made of aluminum, the outer surfaces 42 of at least the corner posts 12', 12'', 12''', 12'''' guided by the upright member 102 should be coated or made of a material other than aluminum to avoid scratches and noise caused by aluminum-to-aluminum sliding during the lifting and lowering of the storage container 106 within the frame structure 100.

[0157] FIG. 1 From FIG. 4C The perspective view shown below reveals more details of the recess in the bottom 10. Additionally, the lifting hole 41 is visible from below.

[0158] FIG. 4A This is a side view of the relatively long side (i.e., the second side 11'' (extending along the X direction)) of the storage container 106 according to the first embodiment. FIG. 4D As can be seen, the upper ends of the first and second corner posts 12', 12'' are at a horizontal level above the top edge 18 of the second side 11''. Furthermore, as shown, the lower ends of the first and second corner posts 12', 12'' are at a horizontal level below the lower end of the second side 11''. This arrangement ensures that the upper ends of the corner posts 12'-12'''' contact the lower side of the corner posts of the storage container above, which again ensures that all or most of the vertical load of the storage container above is supported by the corner posts 12'-12''''.

[0159] FIG. 4Dis a side view of the relatively short side (i.e. Y-direction) of the storage container according to the first embodiment, showing the relative height of the short side (i.e. first side 11’) compared to the height of the first and second corner posts 12’, 12’’.

[0160] FIG. 4E is a top view of the storage container 106 according to the first embodiment.

[0161] FIG. 4F is a top view of the sheet material 13 forming the bottom 10 and the four sides 11’, 11’’, 11’’’, 11’’’’ of the storage container 106 according to the first embodiment. The sheet material 13 can be provided as a blank from which the bottom 10 and the four sides 11’, 11’’, 11’’’, 11’’’’ are made. Each side 11’, 11’’, 11’’’, 11’’’’ is connected to a respective edge 14’, 14’’, 14’’’, 14’’’’ of the bottom 10 by a living hinge provided by a line of weakness 14’, 14’’, 14’’’, 14’’’’.

[0162] The lines of weakness 14’, 14’’, 14’’’, 14’’’’ can be lines of reduced material quantity of the sheet material 13. Alternatively or in addition, the lines of weakness 14’, 14’’, 14’’’, 14’’’’ can comprise through holes 15. As FIG. 4G As shown in Fig. 6, the through holes 15 can occupy a substantial part of the line of weakness, e.g. as shown the through holes can occupy more than 30% of the lines of weakness 14’, 14’’, 14’’’, 14’’’’.

[0163] As shown, in order to simplify folding of the sides 11’, 11’’, 11’’’, 11’’’’ the lines of weakness 14’, 14’’, 14’’’, 14’’’’ can be straight lines.

[0164] As FIG. 4GAs shown in FIG. 1 1, the sheet material 13 can be stamped to provide the profile of the bottom 10 and the four sides 1 1 ', 1 1 ", 1 1 ", 1 1 ". During the step of providing the profile, the stamping process can also form other features, such as the lines of weakness 14', 14", 14", 14" and / or the through holes 15.

[0165] The bottom 10 and sides 1 1 ', 1 1 ", 1 1 ", 1 1 " can be made from a metal sheet material 13, a plastic sheet material 13, a paperboard sheet material 13, a composite sheet material 13, etc. In the case of being made from a metal sheet material 13, the bottom and sides can be made from, for example, an aluminum sheet material 13 or a steel sheet material 13.

[0166] FIG. 4G is a side perspective view of the sheet material in FIG. 4H , where the sides 1 1 ', 1 1 ", 1 1 ", 1 1 " have been folded upward relative to the bottom 10 about 75 degrees to facilitate stacking of the sheet material 13 during shipping.

[0167] FIG. 4G is a side perspective view of the sheet material 13 in FIG. 4I and FIG. 4G , where the sides 1 1 ', 1 1 ", 1 1 ", 1 1 " have been folded upward relative to the bottom 10 about 90 degrees. In this position, two adjacent sides 1 1 '- 1 1 " form a 90 degree angle between them. Further, as seen in FIG. 4H , the distance between the two side edges of one side 1 1 '- 1 1 " is shorter than the distance between the two edges 14'- 14" of the bottom 10, such that the abutting side edges of adjacent sides 1 1 ', 1 1 ", 1 1 ", 1 1 " are insufficient to form a true geometric corner inside the storage container 106, thereby forming an opening 34 between them.

[0168] Reference is now made to FIG. 4I , FIG. 4G , FIG. 4HThe top edge 18 of the storage container forms part of a flange portion 30 of the side 11', 11", 11'", 11"". The flange portion 30 comprises a main portion 31, an intermediate portion 32 and an outer portion 33. The top edge 18 forms an upper end of the outer portion 33. The intermediate portion 32 is folded outwards with respect to the main portion 31 and the outer portion 33 is folded upwards with respect to the intermediate portion 32. Thus, the intermediate portion 32 forms a step or flange between the main portion 31 and the outer portion 33. This construction strengthens the side 11'-11"" as these sides are stiffened by the flange portion 30. In this way, the risk of the storage container to bend is reduced. In order to make the storage container 106 stackable and to maximize the storage volume, the main portion 31 and the outer portion 33 are shown to be parallel.

[0169] As shown in Fig. 1 1, the intermediate portion 32 of the flange portion 30 can comprise a locking hole 35 for locking against a pin member 36 on the corner post 12' (see Fig. 12). FIG. 4I FIG. 4I The corner post 12' - 12"" comprises a first pin member and a second pin member 36 for locking the locking hole 35 in the intermediate portion 32 of the flange portion 30 of the respective side 11'- 11"". The corner post 12' - 12"" is further provided with a snap-lock connection 37 for locking the corner post 12', 12", 12"', 12"" to the flange portion 30. When the outer portion 33 of the flange portion 30 enters a recess 38 provided on the underside of an upper portion of the corner post 12' - 12"", the snap-lock connection 37 comes into contact with the inner surface of the side 11'- 11"" and is forced into connection with the side 11'- 11"".

[0170] FIGS. 5A-5C FIG. 5A FIG. 5B is a detailed view of the corner post 12' - 12"" of the first embodiment of the storage container, wherein FIG. 5C is a side perspective view of the corner post 12' - 12"", FIG. 5A is a top view of the corner post 12' - 12"", and FIG. 5B is a side view of the corner post 12' - 12"".

[0171] The corner post 12' - 12"" comprises a first pin member and a second pin member 36 for locking the locking hole 35 in the intermediate portion 32 of the flange portion 30 of the respective side 11'- 11"". The corner post 12' - 12"" is further provided with a snap-lock connection 37 for locking the corner post 12', 12", 12"', 12"" to the flange portion 30. When the outer portion 33 of the flange portion 30 enters a recess 38 provided on the underside of an upper portion of the corner post 12' - 12"", the snap-lock connection 37 comes into contact with the inner surface of the side 11'- 11"" and is forced into connection with the side 11'- 11"".

[0172] FIG. 5C is an exploded view of the corner post 12' - 12"" and the side 11'- 11"" of the storage container 106 according to the first embodiment.

[0173] FIG. 6 shows a stack 107 of storage containers 106 according to the first embodiment. ​​​

[0174] FIG. 7A is FIG. 7B a detailed view of section G in FIG. 7B is FIG. 7C a simplified view of

[0175] As seen in FIG. 7B and FIG. 7B the disclosed through-hole 15 has an inlet 43 arranged on the inner surface of the storage container 106 and an outlet 44 arranged on the outer surface of the storage container 106. As disclosed, the inlet 43 is arranged at a higher level than the outlet 44 of the through-hole 15. Furthermore, with reference to FIG. 7C and FIG. 7B the centre line 16 of the through-hole 15 forms a negative angle a in relation to the horizontal plane P. The horizontal plane P is shown as being parallel to the bottom 10 of the storage container 106.

[0176] FIG. 7C is FIG. 7D a simplified view of

[0177] In this way, the outer portion 33 of the side can be arranged in all horizontal directions outside any through hole of the storage container supported directly above.

[0178] Therefore, the construction of the flange portion 30 relative to the through hole 15 ensures that water from above (whether from the building's sprinkler system or from the upper storage container 106 or other sources) is guided to the lower storage container 106, thereby providing better fire suppression.

[0179] FIG. 7B This is a perspective view of a stack 107 of storage containers 106 according to the first embodiment, and shows the gap 39 formed between the sides 11'-11'''' of the two storage containers stacked on top of each other.

[0180] FIG. 7E This is a top view showing the position of the side edges of the side portions 11'-11'''' relative to the upright members 102 of the frame structure 100. FIG. 8A Is with FIG. 8B A similar view is shown, in which corner posts 12'-12'''' have been removed. The lengths of the sides 11'-11'''' along the X and Y directions are preferably longer than the distances between the two upright members 102 along the X and Y directions. This positions the side edges of the storage container 106's sides 11'-11'''' relative to the upright members 102 of the ASRS frame structure 100 such that, in the event that corner posts 12'-12'''' melt during a fire and one or more of the four sides 11'-11''''' move outward due to no longer being supported by corner posts 12'-12''''', the sides 11'-11'''' will rest against the upright members 102, as shown by line M. This will maintain the integrity and stability of most of the stack 107 of storage containers and prevent the stack 107 from collapsing.

[0181] FIG. 8A This is an exploded view of the storage container 106 according to the first embodiment, which also includes dividers 50 that divide the capacity of the storage container 106 into separate sections. The dividers 50 are shown as having protrusions 51 on their opposite sides.

[0182] FIG. 9A yes FIG. 9B A detailed view of section L in the image. (See also...) FIG. 9A As shown, the middle portion 32 of the disclosed flange portion 30 has a slot 52 for receiving the protrusion 51 of the separator 50.

[0183] FIG. 9B A transport platform in the form of a pallet 60 is shown, on which two stacks of sheet material 13 with folded sides for transport are placed. FIG. 10Two stacks of partially folded sheet material 13 are shown to lie within the vertical projection of the bottom of the tray 60.

[0184] The storage container 106 according to the first embodiment can be installed on site by the following steps:

[0185] - partially folding each side 11', 11", 11"', 11"" to an angle of between 20 and 85 degrees relative to the base 10;

[0186] - stacking the partially folded sides 11', 11", 11"', 11"" and the base 10 on the tray 60 to at least partially into or within each other;

[0187] - placing the corner posts 12', 12", 12"', 12"" on a platform (not shown in FIG. 10 with corner posts);

[0188] - transporting the stacks of partially folded sides 11', 11", 11"', 11"" and the base 10 and the corner posts 12', 12", 12"', 12"" to the site of the ASRS;

[0189] - assembling the storage container 106 on site.

[0190] The steps of assembly can include:

[0191] - fully folding the sides 11', 11", 11"', 11"" so that each side extends at 90 degrees from the base 10;

[0192] - sliding each corner post 12', 12", 12"', 12"" in from above to lockingly engage with the edges of a pair of adjacent sides 11', 11", 11"', 11""; and

[0193] - snap locking the corner posts 12', 12", 12"', 12"" to the flange portions 30 of the storage container 106 to lockingly engage the corner posts 12', 12", 12"', 12"" with the side edges of the adjacent sides 11', 11", 11"', 11"".

[0194] Second embodiment of a storage container

[0195] A first embodiment of an automated storage and retrieval system according to the present application will now be discussed in more detail with reference to Figures 11 to 13.

[0196] Several features are similar to the first embodiment described in detail above. Different features and functions will be described below. Common features will not be repeated.

[0197] FIG. 10 is a perspective view of a storage container 106 according to the second embodiment. The figure shows a storage container 106 of an automated storage and retrieval system ASRS 1. The storage container 106 is configured to be stacked in a manner of stacks of storage containers 106, wherein a lower storage container 106 supports one or more storage containers 106 positioned above. The storage container 106 comprises a hoist hole 41, such that the storage container is adapted to be lifted by a clamp 304 (see FIG. 11A ) on a lifting device, such that the storage container 106 can be lifted from above. The disclosed storage container 106 has a rectangular base 10; four side portions 11’, 11”, 11’”, 11””, each side portion being hingedly connected to an edge 14’, 14”, 14’”, 14”” of the base 10; four corner posts 12’, 12”, 12’”, 12””, each corner post being configured to interconnect a pair of adjacent side portions 11’, 11”, 11’”, 11”” in a horizontal direction to each other when the pair of adjacent side portions 11’, 11”, 11’”, 11”” are positioned at approximately 90 degrees in relation to the base 10 and to each other. A first short side portion 11’ (i.e. “first side portion”) is connected to a first long side portion 11” (i.e. “second side portion”) via a first corner post 12’. The first long side portion 11” (i.e. “second side portion”) is further connected to a second short side portion 11’” (i.e. “third side portion”) via a second corner post 12”. The second short side portion 11’” (i.e. “third side portion”) is connected to a second long side portion 11”” (i.e. “fourth side portion”) via a third corner post 12’”. The second long side portion 11”” (i.e. “fourth side portion”) is connected to the first short side portion 11’ (i.e. “first side portion”) via a fourth corner post 12””.

[0198] The disclosed side portions 11’-11”” and base 10 have recesses 40 to increase strength. The disclosed side portions 11’-11”” have recesses extending in a vertical direction (when the side portions 11’-11”” are folded upwards). The recesses are shaped (i.e. not through holes). Similarly, the disclosed base 10 has a recess extending from the second side portion 11” towards the fourth side portion 11”” (i.e. between the first and second long side portions 11”, 11”” of the base 10).

[0199] FIG. 3 is a side view of a long side portion (i.e. second side portion 11”) of a storage container 106 according to the second embodiment.

[0200] FIG. 11B is a side view of a short side (i.e. first side 11’) of the storage container 106 according to the second embodiment.

[0201] FIG. 11C is a top view of the storage container 106 according to the second embodiment.

[0202] FIG. 11D is a bottom view of the storage container 106 according to the second embodiment.

[0203] FIG. 11E is a detailed view of section C in FIG. 11F As shown in FIG. 11E , the disclosed fourth corner post 12’’’’ has a longitudinal notch 17 on the outer surface. This longitudinal or vertical notch 17 helps enable the storage container 106 to be lifted by a clamp 304 (see FIG. 11F ) on a lifting device, as the box guide (not shown) of the lifting device can be guided along the notch 17 on the different corner posts 12’, 12”, 12’”, 12’’”.

[0204] The disclosed corner post 12’” also has an outer surface 42 for sliding contact with the upright member 102 (see FIG. 3 ) of the frame structure 100. If the upright member 102 is made of aluminum, at least the outer surface 42 of the corner posts 12’, 12”, 12’”, 12’’” guided by the upright member 102 should be coated or made of another material than aluminum to avoid scratches and noise due to aluminum-on-aluminum sliding during lifting and lowering of the storage container 106 within the frame structure 100.

[0205] FIG. 1 is a view along line D-D in FIG. 11G The disclosed locking frame 70 has a snap lock connection 37 for locking the corner post 12’. The snap lock connection 37 extends downward from the underside of the locking frame 70 to lockingly contact the recess 72 on the top edge 18 of the side 11’-11’’” and the upper end of the corner post 12’-12’’” (as better shown in FIG. 11B and FIG. 12B ).

[0206] FIG. 12C is a top view of the sheet material 13 forming the bottom 10 and the four sides 11’-11’’” of the storage container 106 according to the second embodiment.

[0207] FIG. 12Ais a top view of a sheet material 13 forming a bottom 10 and four side portions 11', 11", 11"', 11"" of a storage container 106 according to a second embodiment. The sheet material 13 can be provided as a blank from which the bottom 10 and the four side portions 11', 11", 11"', 11"" are made. Each side portion 11', 11", 11"', 11"" is connected to a respective edge 14', 14", 14"', 14"" of the bottom 10 by a living hinge provided by a line of weakness 14', 14", 14"', 14"". The line of weakness 14', 14", 14"', 14"" extends between each side portion 11', 11", 11"', 11"" and the bottom 10 such that the respective side portion 11', 11", 11"', 11"" can be folded relative to the bottom 10 along the line of weakness 14', 14", 14"', 14"". In particular, a first line of weakness 14' extends between a first edge of the bottom 10 and the first side portion 11', a second line of weakness 14" extends between a second edge of the bottom 10 and the second side portion 11", a third line of weakness 14'" extends between a third edge of the bottom 10 and the third side portion 11"', and a fourth line of weakness 14"" extends between a fourth edge of the bottom 10 and the first side portion 11"". In this way, the bottom and the side portions can be made from the same material.

[0208] The lines of weakness 14', 14", 14"', 14"" can be lines of reduced material quantity of the sheet material 13. Alternatively or in addition, the lines of weakness 14', 14", 14"', 14"" can comprise through holes 15. As shown in FIG. 12A The through holes 15 can occupy a majority of the lines of weakness, for example, as shown, the through holes can occupy more than 30% of the lines of weakness 14', 14", 14"', 14"".

[0209] As shown, to simplify folding of the side portions 11', 11", 11"', 11"", the lines of weakness 14', 14", 14"', 14"" can be straight lines.

[0210] As shown in FIG. 12A The sheet material 13 can be stamped to provide the contours of the bottom 10 and the four side portions 11', 11", 11"', 11"".

[0211] The bottom 10 and the side portions 11', 11", 11"', 11"" can be made of a metal sheet material 13, a plastic sheet material 13, a paperboard sheet material 13, a composite sheet material 13, etc. In case of being made of a metal sheet material 13, the bottom and the side portions can be made of, for example, an aluminum sheet material 13 or a steel sheet material 13.

[0212] The top edges 18 of the second and fourth side portions 11", 11"" are formed with pre-cut slits 80 at locations complementary to the hoisting holes 41 in the locking frame 70.

[0213] FIG. 12A is FIG. 12B a side view perspective of the sheet material in , wherein the side portions 11'-11"" have been folded upwards in relation to the bottom 10 in approximately 90 degrees. In this position, two adjacent side portions 11'-11"" form an angle of 90 degrees between them. Furthermore, as seen in FIG. 12A , the distance between the two side edges of one side portion 11'-11"" is shorter than the distance between the two edges 14'-14"" of the bottom 10, so that the abutting side edges of adjacent side portions 11', 11", 11"', 11"" are not enough to form a true geometric angle inside the storage container 106, thereby forming an opening 34 between them.

[0214] Reference is now made to FIG. 12B and FIG. 12A , the top edges 18 of the storage container form part of a top portion 90 of the side portions 11', 11", 11"', 11"". The top portion 90 comprises a main top portion 91 and a folded portion 92. The top edges 18 form the folded portion 92. The folded portion 92 is folded outwards in relation to the main top portion 91. Thus, the folded portion 92 forms a flat platform on top of the side portions 11'-11"". This construction strengthens the side portions 11'-11"", as these are stiffened by the top portion 90. In this way, the risk of the storage container bending is reduced.

[0215] FIG. 12B is an exploded view of the corner posts 12'-12"", the side portions 11'-11"" and the locking frame 70 of the storage container 106 according to the second embodiment. In each corner of the bottom 10 is shown a corner post receiver 71 for receiving a corner post 12'-12"".

[0216] Reference is made to FIG. 12C , FIG. 12A and FIG. 12BEach side portion 11', 11", 11"', 11"" is shown as having a top edge 18 and two opposite side edges. Each side portion 11', 11", 11"', 11"" is folded over, forming a fold 20 at the side edges FIG. 12C (not shown in FIGS. 12A-12C ), to provide an outwardly extending rib 19 at each side edge. Each corner post 12', 12", 12"', 12"" includes a pair of grooves 21 (see FIG. 11F for details) extending along its longitudinal direction for receiving respective outwardly extending ribs 19 from a pair of adjacent side portions 11', 11", 11"', 11"".

[0217] When the top edge 18 is folded so that the folded top portion 92 points upward as shown in FIG. 11F , the closure lock frame 70 locks all of the top edges 18 of the side portions 11', 11", 11"', 11"" relative to the corner posts 12', 12", 12"', 12"" relative to each other. The top edges 18 and the corner posts 12', 12", 12"', 12"" can have open upwardly oriented recesses 72, and the lock frame 70 can have complementary downwardly oriented protrusions 37 for locking with the recesses 72, thereby snap locking the lock frame 70 to the side portions 11'-11"" and the corner posts 12'-12"".

[0218] FIG. 12C A transport platform in the form of two stacks of trays 60 on which two stacks of side portions 11'-11"" of the partially folded sheet material 13 are placed, and another transport platform in the form of a tray 60 on which a stack of lock frames 70 is placed, are shown. Both trays 60 are used for transport.

[0219] FIG. 13A is a view from a short side of the tray 60 with the stack of lock frames 70 in FIG. 13B .

[0220] FIG. 13A is a top view of the tray 60 with the stack of lock frames 70 in FIG. 13C and FIG. 13A .

[0221] FIG. 13B is a view from a short side of the tray 60 with the stack of side portions 11'-11"" of the partially folded sheet material 13 in FIG. 13D .

[0222] FIG. 13A is a top view of the tray 60 with the stack of side portions 11'-11"" of the partially folded sheet material 13 in FIG. 13E and FIG. 13Aa top view of the tray 60 with the stacked partially folded sheet material 13 of the side portions 11'- 11 '' ''. As shown, both stacks of the partially folded sheet material 13 of the side portions 11'- 11 '' '' are within the vertical projection of the bottom of the tray 60, making transportation efficient.

[0223] The storage container can then be installed on site by the following steps:

[0224] - folding each side portion 11 ', 11 '', 11 '' ', 11 '' '' partially at an angle of between 20 and 85 degrees relative to the bottom 10;

[0225] - stacking the partially folded side portions 11 ', 11 '', 11 '' ', 11 '' '' and the bottom 10 on the tray 60 to at least partially enter or lie within each other;

[0226] - placing the corner posts 12 ', 12 '', 12 '' ', 12 '' '' on a platform (not shown) in the FIG. 13D FIG. 10

[0227] - transporting the stacks of the partially folded side portions 11 ', 11 '', 11 '' ', 11 '' '' and the bottom 10 and the corner posts 12 ', 12 '', 12 '' ', 12 '' '' to the site of the ASRS;

[0228] - assembling the storage container 106 on site.

[0229] The step of assembling the storage container 106 on site can comprise:

[0230] - folding each side portion 11 ', 11 '', 11 '' ', 11 '' '' fully so that each side portion extends at 90 degrees from the bottom 10;

[0231] - sliding each corner post 12 ', 12 '', 12 '' ', 12 '' '' in from above to lockingly engage with the edges of a pair of adjacent side portions 11 ', 11 '', 11 '' ', 11 '' ''.

[0232] The final step of assembling the storage container according to the second embodiment can comprise:

[0233] - locking the locking frame 70 to the side portions 11 ', 11 '', 11 '' ', 11 '' '' and the corner posts 12 ', 12 '', 12 '' ', 12 '' ''. The locking of the locking frame 70 to the side portions 11 ', 11 '', 11 '' ', 11 '' '' and the corner posts 12 ', 12 '', 12 '' ', 12 '' '' can be achieved via a snap lock between the recesses 72 and the protrusions 37 of the connecting portions 37. ​

[0234] In the foregoing description, numerous specific details have been set forth to provide a thorough understanding of the present application. One skilled in the relevant art will recognize, however, that the overall scope of the application can be practiced without combining all of the features. Indeed, other embodiments of the present application can be practiced or carried out in various ways. For example, the present application can be practiced or carried out using storage containers and automated storage and retrieval systems having configurations other than those described above. Furthermore, certain portions of the procedures and methods described above can be implemented or performed by one or more computing devices or processors. Accordingly, other embodiments of the present application can be practiced or carried out in other ways not expressly described or shown in this patent document. Additionally, the present application is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the claims, the principles and terminology described herein.

[0235] List of references:

[0236]

Claims

1. A storage container (106) for an automated storage and retrieval system, ASRS (1), the storage container (106) being configured to be stacked in a stack of storage containers (106) in which a lower storage container (106) supports one or more storage containers (106) positioned above, the storage container (106) being adapted to be lifted by a clamp (304) on a lifting device such that the storage container (106) can be lifted from above, wherein, The storage container (106) comprises: a bottom (10); four side portions (11', 11'', 11''', 11''”), each hingedly connected to an edge (14', 14'', 14''', 14””) of the bottom (10); four corner posts (12', 12'', 12''', 12””), each configured to interconnect a pair of adjacent side portions (11', 11'', 11''', 11””) in a horizontal direction to each other when the pair of adjacent side portions (11', 11'', 11''', 11””) are positioned at substantially 90 degrees relative to the bottom (10) and to each other, and wherein each of the side portions (11', 11'', 11''', 11””) comprises a top edge (18) and two opposite side edges, and wherein each of the side portions (11', 11'', 11''', 11””) is folded to form a fold (20) at the side edges, thereby providing an outwardly extending rib (19) at each side edge, and wherein each corner post (12', 12'', 12''', 12””) comprises a pair of grooves (21) extending in a longitudinal direction of the corner post for receiving a respective outwardly extending rib (19) of a pair of adjacent side portions (11', 11'', 11''', 11””).

2. The storage container (106) of claim 1, wherein, The bottom (10) and the side portions (11', 11'', 11''', 11””) of the storage container (106) comprise a sheet material (13) provided as a blank from which the bottom (10) and the four side portions (11', 11'', 11''', 11””) are made, wherein each of the side portions (11', 11'', 11''', 11””) is connected to a respective edge (14', 14'', 14''', 14””) of the bottom (10) by a living hinge provided by a line of weakness (14', 14'', 14''', 14””), the line of weakness extending between each of the side portions (11', 11'', 11''', 11””) and the bottom (10) such that the respective side portion (11', 11'', 11''', 11””) can be folded relative to the bottom (10) along the line of weakness (14', 14'', 14''', 14””).

3. The storage container (106) of claim 2, wherein, The line of weakness (14', 14'', 14''', 14””) is a line of reduced material quantity of the sheet material (13).

4. The storage container (106) according to claim 2 or 3, wherein The line of weakness (14', 14'', 14''', 14””) comprises a through hole (15).

5. The storage container (106) of claim 4, wherein, The through hole (15) comprises more than 30% of the line of weakness (14', 14'', 14''', 14””).

6. The storage container (106) of claim 4, wherein, The cross-sectional area of the through hole (15) has a size sufficient for water to flow through.

7. The storage container (106) of claim 4, wherein, The through hole (15) comprises: - an inlet (43) arranged on an inner surface of the storage container (106); and - an outlet (44) arranged on an outer surface of the storage container (106); and wherein the inlet (43) is arranged at a height equal to or higher than the outlet (44) of the through hole (15).

8. The storage container (106) according to claim 2 or 3, wherein, The line of weakness (14', 14'', 14''', 14''”) is a straight line.

9. The storage container (106) according to claim 2 or 3, wherein, The sheet material (13) is punched to provide the profile of the bottom (10) and the four side portions (11', 11'', 11''', 11''”).

10. The storage container (106) according to any one of claims 1 to 3, wherein, The bottom (10) and the side portions (11', 11'', 11''', 11''”) are made of a metal sheet material (13), a plastic sheet material (13), a paperboard sheet material (13) or a composite sheet material (13).

11. The storage container (106) of claim 10, wherein, The bottom (10) and the side portions (11', 11'', 11''', 11''”) are made of aluminum or steel.

12. The storage container (106) according to any one of claims 1 to 3, wherein, The height of the corner post (12', 12'', 12''', 12''”) is at least the same as the height of the side portion (11', 11'', 11''', 11''”).

13. The storage container (106) according to any one of claims 1 to 3, wherein, The upper end of the corner post (12', 12'', 12''', 12''”) is at the same level or higher than the upper end of the side portion (11', 11'', 11''', 11''”).

14. The storage container (106) according to any one of claims 1 to 3, wherein, The lower end of the corner post (12', 12'', 12''', 12''”) is at the same level or lower than the lower end of the side portion (11', 11'', 11''', 11''”).

15. The storage container (106) according to any one of claims 1 to 3, wherein, The corner post (12', 12'', 12''', 12''”) is made of a plastic material.

16. The storage container (106) according to any one of claims 1 to 3, wherein, The corner post (12', 12'', 12''', 12''”) comprises a longitudinal notch (17) on an outer surface of the corner post.

17. The storage container (106) of claim 1, wherein, The distance between the two side edges of one side portion (11'-11''”) is shorter than the distance between the two edges (14'-14''”) of the bottom (10), so that the adjoining side edges of adjacent side portions (11', 11'', 11''', 11''”) are not sufficient to form a true geometric corner inside the storage container (106).

18. The storage container (106) of claim 4, wherein, The top edge forms part of a flange portion (30) of the side portion (11', 11'', 11''', 11''”), wherein the corner post (12', 12'', 12''', 12''”) comprises a snap-lock connection for locking the corner post (12', 12'', 12''', 12''”) to the flange portion (30).

19. The storage container (106) of claim 18, wherein, The flange portion (30) comprises a main portion (31), an intermediate portion (32) and an outer portion (33), wherein the top edge (18) forms an upper end of the outer portion (33).

20. The storage container (106) of claim 19, wherein, The intermediate portion (32) is folded outwards relative to the main portion (31), and the outer portion (33) is folded upwards relative to the intermediate portion (32).

21. The storage container (106) according to claim 19 or 20, wherein The main portion (31) and the outer portion (33) are substantially parallel.

22. The storage container (106) according to claim 19 or 20, wherein The cross-sectional area formed by the outer portion (33) of the side portion (11', 11'', 11''', 11'''') is larger than the base portion (10) in all directions, and thus, the through-going hole (15) of the base portion (10) of a storage container (106) positioned directly above causes all water flowing through the through-going hole (15) of the storage container (106) above to be directed into the storage container (106) via the outer portion (33), the intermediate portion (32) and the main portion (31) of the flange portion (30).

23. The storage container (106) of claim 1 or 17, wherein, The top edge (18) is folded to form a folded portion (92), and wherein the storage container (106) further comprises a closure locking frame (70) for locking all the top edges of the side portions (11', 11'', 11''', 11'''") and the corner posts (12', 12'', 12''', 12''") relative to each other.

24. The storage container (106) of claim 23, wherein, The top edge (18) and the corner posts (12', 12'', 12''', 12''") comprise open upwardly directed recesses (72), and the locking frame (70) comprises complementary downwardly directed protrusions (37) for locking with the recesses (72).

25. An automated storage and retrieval system (1) comprising a two-dimensional rail system (108), the two-dimensional rail system comprising: a first set of parallel tracks (110a,b) arranged to guide the container handling vehicles (301) to move in a first direction (X) on top of the frame structure (100); and a second set of parallel tracks (111a,b) arranged perpendicular to the first set of parallel tracks (110a,b) to guide the container handling vehicles (301) to move in a second direction (Y) perpendicular to the first direction (X), wherein a plurality of container handling vehicles are operating on the rail system (108), and wherein the system (1) comprises one or a plurality of storage containers (106) according to any of the preceding claims 1-24.

26. A method of transporting and assembling a storage container (106) on site, wherein, The storage container (106) comprises: a base portion (10); four side portions (11', 11'', 11''', 11'''") each hingedly connected to an edge of the base portion (10); four corner posts (12', 12'', 12''', 12''") each configured to interconnect a pair of adjacent side portions (11', 11'', 11''', 11'''") to each other in a horizontal direction when the pair of adjacent side portions (11', 11'', 11''', 11'''") are positioned at substantially 90 degrees relative to the base portion (10) and to each other; and wherein the method comprises the steps of: - partially folding each of the side portions (11', 11'', 11''', 11'''') to an angle of between 20 and 85 degrees relative to the base portion (10); - stacking the partially folded side portions (11', 11'', 11''', 11'''') and the base portion (10) at least partially into or within each other on a common transport platform (60); - placing the corner posts (12', 12'', 12''', 12'''') on the platform; - transporting the stack of partially folded side portions (11', 11'', 11''', 11'''') and the base portion (10) and the corner posts (12', 12'', 12''', 12'''') to the site of the ASRS; - assembling the storage container (106) on site, wherein each of the side portions (11', 11'', 11''', 11'''') comprises a top edge and two opposite side edges, and wherein each of the side portions (11', 11'', 11''', 11'''') is folded to form a fold (20) at the side edges, thereby providing an outwardly extending rib (19) at each side edge, and wherein each corner post (12', 12'', 12''', 12'''') comprises a pair of grooves (21) extending in the longitudinal direction of the corner post for receiving a corresponding outwardly extending rib (19) of a pair of adjacent side portions (11', 11'', 11''', 11''''), and the step of assembling the storage container (106) on site comprises: - fully folding the side portions (11', 11'', 11''', 11'''') such that each side portion extends at 90 degrees from the base portion (10); - sliding each of the corner posts (12', 12'', 12''', 12'''') in from above into locking engagement with the edges of a pair of adjacent side portions (11', 11'', 11''', 11'''').

27. The method of claim 26, wherein, The top edge forms part of a flange portion (30) of the side portions (11', 11'', 11''', 11''''), wherein the corner posts (12', 12'', 12''', 12'''') comprise a snap-lock connection for locking the corner posts (12', 12'', 12''', 12''') to the flange portion (30), and the method further comprises: - snap-locking the corner posts (12', 12'', 12''', 12''') to the flange portion (30) of the storage container (106) to bring the corner posts (12', 12'', 12''', 12''') into locking engagement with the side edges of adjacent side portions (11', 11'', 11''', 11''').

28. The method of claim 26, wherein, The top edges have been folded, and wherein the storage container (106) further comprises a closure locking frame (70) for locking all the top edges of the side portions (11', 11'', 11''', 11'''' ) and the corner posts (12', 12'', 12''', 12'''') relative to each other, the method comprising the steps of: - locking the locking frame (70) to the side portions (11', 11'', 11''', 11'''') and the corner posts (12', 12'', 12''', 12'''').

29. The method of claim 28, wherein, The top edges and the corner posts (12', 12'', 12''', 12'''') comprise open upwardly directed recesses (72), and the locking frame (70) comprises complementary downwardly directed protrusions (37) for locking with the recesses (72), and wherein the method comprises: - locking the locking frame (70) to the side portions (11', 11'', 11''', 11'''') and the corner posts (12', 12'', 12''', 12'''') via the recesses (72) and the protrusions (37).

30. A method of field assembling a storage container (106) according to any of the preceding claims 1 to 24 at an ASRS, wherein, The method comprises the steps of: - folding each of the side portions (11', 11'', 11''', 11'''') completely so that each side portion extends at 90 degrees to the bottom portion (10); - sliding each of the corner posts (12', 12'', 12''', 12'''') in from above into locking engagement with the edges of a pair of adjacent side portions (11', 11'', 11''', 11''''); - snap locking the corner posts (12', 12'', 12''', 12'''') to the flange portions (30) of the storage container (106) to lock the corner posts (12', 12'', 12''', 12'''') in locking engagement with the edges of the adjacent side portions (11', 11'', 11''', 11'''').

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