Grid framework structure

Abstract

To provide a grid framework structure for supporting a remote-operable cargo-handling device placed on the grid framework structure for handling storage containers or bottles stacked in the grid framework structure.SOLUTION: A grid framework structure comprises a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, to form a grid structure 140 having a plurality of grid cells 42 present in a horizontal plane and a plurality of vertical upright materials 116 for supporting the grid structure 140 that allows a cargo-handling device 30 operating on the grid structure 140 to make a storage space for storing containers in a stack, so that a section of the grid structure 140 having four adjacent grid cells is arranged in a manner supported by five or less vertical upright materials 116.SELECTED DRAWING: Figure 13

Description

[Technical field]

[0001] The present invention relates to the field of remotely operated load handling devices on trucks positioned on a grid framework structure for handling storage containers or bins stacked on the grid framework structure, and more particularly to a grid framework structure for supporting the remotely operated load handling devices. [Background technology]

[0002] Storage systems 1 comprising a three-dimensional storage grid framework structure in which storage containers / bins are stacked on top of each other are well known. PCT Publication No. WO2015 / 185628A (Ocado) describes a known storage and fulfilment or delivery system in which a stack of bins or containers are arranged within a grid framework structure. The bins or containers are accessed by remotely operated material handling devices on trucks that are positioned on top of the grid framework structure. This type of system is shown diagrammatically in Figures 1 to 3 of the accompanying drawings.

[0003] As shown in Figures 1 and 2, stackable containers known as storage bins or containers 10 are stacked on top of one another to form a stack 12. The stack 12 is arranged in a grid framework structure 14 in a warehouse or manufacturing environment. The grid framework is made up of a number of storage or grid posts. Each grid of the grid framework structure has at least one grid post for storing a stack of containers. Figure 1 is a schematic perspective view of the grid framework structure 14, and Figure 2 is a top-down view showing a stack 12 of bins 10 arranged within the framework structure 14. Each bin 10 typically holds multiple product items (not shown), which may be the same or different product types depending on the application.

[0004] In particular, the grid framework structure 14 comprises a plurality of vertical uprights or upright members or upright columns 16 that support horizontal grid members 18, 20. A first set of parallel horizontal grid members 18 are arranged perpendicular to a second set of parallel horizontal grid members 20 to form a grid structure or grid 15 comprising a plurality of grid cells 17. The grid cells have openings that allow a loading device to lift a container or storage bin through the grid cell. In the grid structure, the first set of parallel horizontal grid members 18 intersect with the second set of parallel horizontal grid members at nodes. The grid structure is supported by the upright members 16 at each of the nodes or points where the grid members intersect such that the upright members are interconnected at their upper ends by the intersecting grid members. The grid members 16, 18, 20 are typically fabricated from metal and are typically welded or bolted together or a combination of both. The storage bins or containers 10 are stacked between upright members 16 of a grid framework structure 14 such that the uprights 16 prevent horizontal movement of the stack 12 of bins 10 and guide vertical movement of the storage bins 10.

[0005] The upper level of the grid framework structure 14 includes rails 22 arranged in a grid pattern across the top of the stack 12. With further reference to FIG. 3 , the rails 22 support a plurality of load handling devices 30. A first set 22a of parallel rails 22 guides movement of the robotic load handling device 30 in a first direction (e.g., X direction) across the top of the grid framework structure 14, and a second set 22b of parallel rails 22 arranged perpendicular to the first set 22a guides movement of the load handling device 30 in a second direction (e.g., Y direction) perpendicular to the first direction. In this manner, the rails 22 enable lateral movement of the robotic load handling device 30 in two dimensions in the horizontal XY plane, such that the load handling device 30 can be moved to a position above any of the stacks 12.

[0006] A known load handling device, also known as a bot 30, shown in Figures 4 and 5, is described in PCT Patent Publication No. WO2015 / 019055 (Ocado), which is incorporated herein by reference, comprising a car body 32, with each load handling device 30 covering only a single grid space or grid cell of a grid framework structure 14. Here, the load handling device 30 comprises a wheel assembly comprising a first set of wheels 34 consisting of a pair of wheels at the front of the car body 32 for engaging with a first set of rails or tracks to guide the movement of the device in a first direction, a pair of wheels 34 at the rear of the car body 32, and a second set of wheels 36 consisting of a pair of wheels 36 on either side of the car body 32 for engaging with a second set of rails or tracks to guide the movement of the device in a second direction. Each of the wheel sets is driven to allow the vehicle to move in the X and Y directions respectively along the rails. One or both sets of wheels can be moved vertically to lift each set of wheels off of its respective rail, thereby allowing the vehicle to move in a desired direction, for example in the X or Y direction on the grid structure.

[0007] The handling device 30 includes a lifting device or crane mechanism for lifting the storage container from above. The crane mechanism comprises a winch tether or cable 38 wound on a spool or reel (not shown) and a grabber device 39 in the form of a lifting frame. The lifting device comprises a set of lifting tethers 38 extending vertically and connected near or to the four corners of the lifting frame 39, also known as a grabber device (one tether near each of the four corners of the grabber device) for releasably connecting to the storage container 10. The grabber device 39 is configured to releasably grip the top of the storage container 10 to lift it from a stack of containers in a storage system of the type shown in Figures 1 and 2.

[0008] The wheels 34, 36 are arranged around the periphery of a cavity or recess known as the lower container receiving recess or container receiving space 41. The recess is sized to accommodate the container 10 when it is lifted by the crane mechanism as shown in Figure 5 (a and b). When in the recess, the container is lifted from the rail below to allow the vehicle to move laterally to another location. Upon reaching the target location, for example another stack, an access point in a storage system, or a conveyor belt, the bin or container can be lowered from the container receiving portion and released from the grabber device. The container receiving space may comprise a cavity or recess located within the vehicle body, for example as described in WO2015 / 019055 (Ocado Innovation Limited). Alternatively, the vehicle body of the load handling device may comprise a cantilever as taught in WO2019 / 238702 (Autostore Technology AS), in which case the container receiving space is located below the cantilever of the load handling device. In this case, the grabber device is lifted by the cantilever such that the grabber device can engage and lift a container from the stack into a container receiving space below the cantilever.

[0009] To ensure the stability of the grid framework structure, prior art storage systems rely heavily on various supports and bracings positioned within or at least partially along the perimeter of the grid framework structure. However, the use of various supports and braces (anti-shift braces) to stabilize the grid framework structure from internal and external forces is disadvantageous for a number of reasons. The grid framework structure takes up space or area available for storing containers in that it prevents optimal use of the space or area available for container storage. Because auxiliary grid support structures often require connections to surrounding structures such as interior walls of a building, the need for support structures can limit the options available for positioning the grid framework structure. The requirement for support structures to stabilize the grid framework structure is generally not cost-effective and takes up useful storage space.

[0010] WO2019 / 101367 (Autostore Technology AS) teaches an independent storage grid that requires less auxiliary grid support structures by incorporating a grid support structure into the storage grid structure. The grid support structure is composed of four storage columns interconnected by a plurality of vertically inclined support struts. The storage column profile has a cross section including a hollow central section and four corner sections, each corner section including two vertical bin guide plates for accommodating the corners of a storage bin. The support struts have a width that allows them to fit between two parallel guide plates so as not to impair the storage column's ability to accommodate a stack of containers or storage bins.

[0011] To construct a grid framework structure in the art, a plurality of vertical uprights are individually positioned in a grid-like pattern on the ground. The height of the vertical uprights, and therefore the level of the grid attached thereto, is adjusted by one or more adjustable feet at the base or bottom end of each of the vertical uprights. To provide structural stability to the grid framework structure, subgroups of the vertical uprights are braced together. The vertical uprights are interconnected at their upper ends by grid members such that the grid members adopt the same grid pattern as the vertical uprights. That is, the vertical uprights support the grid members at the points where the grid members intersect in the grid pattern. For purposes of the present description, the points or junctions where the grid members intersect or are interconnected constitute the nodes of the grid structure and correspond to the areas where the grid structure is supported by the vertical uprights. The resulting grid framework structure can be considered as an independent linear collection of uprights supporting a grid formed from intersecting horizontal grid members, i.e., a four-walled framework.

[0012] The arrangement of vertical uprights provides multiple vertical storage columns for storing one or more containers in a stack. The vertical uprights help guide the grabber device of the lifting mechanism as it engages the container in the grid framework structure and lifts it towards the handling device operating on the grid. The size of the grid framework structure, and therefore its ability to store containers containing various items and stock keeping units (SKUs), is highly dependent on the number of vertical uprights that span the specific footprint of the grid framework structure. However, one of the biggest bottlenecks in building a fulfillment or distribution center is the construction of the grid framework structure. The time and cost to assemble the grid framework structure accounts for a large portion of the time and cost to build a fulfillment or distribution center. The largest and most time-consuming operation is individually constructing the vertical uprights and fastening the grid structure to the vertical uprights.

[0013] Thus, there is a need for a grid framework structure that can be constructed more quickly and / or less expensively than current grid framework structures in the art. Additionally, there is also a need for the grid framework structure to maximize the space or area available for storage of multiple containers.

[0014] This application claims priority from UK patent application number 2012740.3 filed on August 14, 2020, UK patent application number 2012751.0 filed on August 14, 2020, UK patent application number 2013968.9 filed on September 4, 2020, UK patent application number 2016081.8 filed on October 9, 2020, and UK patent application number 2016097.4 filed on October 9, 2020, the contents of which are incorporated herein by reference. Summary of the Invention

[0015] The present invention alleviates the above problems by providing a grid framework structure configured to support one or more load handling devices, said grid framework structure comprising: i) a first set of grid members extending in a first direction; ii) a second set of grid members extending in a second direction, the first direction being substantially perpendicular to the second direction, forming a grid structure comprising a plurality of grid cells that lie in a horizontal plane; and iii) a plurality of vertical uprights for supporting the grid structure above the ground to create space for storing one or more containers in a stack such that, in use, one or more loading devices operating on the grid can lift one or more containers from the stack below the grid structure through the grid cells, wherein the plurality of vertical uprights are arranged such that a section of the grid structure comprising four adjacent grid cells is supported by no more than five vertical uprights.

[0016] Conventional wisdom in the industry is of the opinion that the grid structure is supported by vertical uprights at each node or junction where the grid members cross or are interconnected, which (i) support one or more load handling devices operating on the grid structure, and (ii) help guide the grabber devices of the load handling devices to engage containers in the stack. Each of the vertical uprights can be considered to act as a structural element under compression to support the grid structure above. However, in contrast to conventional wisdom, the present invention has recognized that the grid structure can be supported by fewer vertical uprights than are currently required at each node of the grid structure. More specifically, the support of the grid structure is such that a section or portion of the grid structure comprising four adjacent grid cells may be supported by five or fewer vertical uprights. For the purposes of the present invention, the term "adjacent" in the context of a grid structure is limited to a set of four adjacent grid cells, i.e., each grid cell in a section is directly adjacent to one another or in a 2×2 grid arrangement. In the present invention, a section or at least a portion of the grid structure comprising four adjacent grid cells is supported by five or fewer vertical uprights. The section of four adjacent grid cells may be located anywhere within the grid structure. Optionally, the section of the grid structure comprises a corner section of the grid structure.

[0017] There are different examples of the present invention where this is possible. In a first embodiment of the present invention, the grid structure preferably has a rectangular or square configuration with four corner sections, each corner section being supported by a single vertical upright. By supporting the grid structure at its corners, an open storage space is created below the grid structure for storing one or more containers in a stack. While conventional wisdom requires grabber devices of the lifting mechanism and the containers of the stack below the grid structure to be guided along storage columns cooperating with vertical uprights at all four corners of the container as they are lifted or hoisted towards a handling device operating on the grid structure to prevent the containers from swaying from side to side, the present invention defies such conventional wisdom by allowing the containers to be lifted in free space towards the grid, i.e. without vertical uprights to guide the containers. In the present invention, it is recognized that the grabber device and lifting tethers used to engage and lift the container from the storage column towards the grid structure are sufficiently stable to lift the container vertically through the grid cells towards the handling device without undue swaying, fouling or impinging on another container from the grid cell or adjacent stack as the container approaches the grid. Typically, the handling device is equipped with a lifting device or crane device arranged to lift the storage container from above. The lifting device is also known as a grabber device (one tether near each of the four corners of the grabber device) that extends vertically and comprises a set of lifting tethers connected near or at the four corners of the lifting frame for releasable connection to the storage vessel 10. The grabber device is configured to releasably grip the top of the storage container to lift it from the stack of containers in a storage system of the type shown in Figures 1 and 2. The lifting tethers supporting the grabber device at the four corners are sufficiently stable to lift the container vertically along a vertical axis towards the grid structure or with little or no swaying of the grabber device and the container it engages.

[0018] This allows multiple adjacent stacks of containers to be stored side by side, with each stack of containers located under a respective grid cell such that a loading and unloading device operating on the grid structure can hoist the associated container from storage. By removing the vertical uprights to guide the containers towards the grid structure, the effect of the vertical uprights affecting the space or area available for storage of containers can be minimized. As a result, one or more stacks of containers can be stored closer together, thereby occupying the space once occupied by the vertical uprights.

[0019] In order to improve the structural integrity and stability of the grid framework structure as an independent structure, preferably the vertical uprights are braced by at least one bracing member. Optionally, the at least one bracing member extends longitudinally between the tops of the vertical uprights to form a substantially rectangular or square perimeter bracing structure or frame. Optionally, the at least one bracing member is a diagonal bracing member or a straight horizontal bracing member. Bracing four vertical uprights by a straight horizontal bracing member forms at least one drag strut or collector, as is commonly known in the art. The drag strut or collector is where at least two vertical uprights are braced by a horizontal frame beam at the top of the two vertical uprights, and serves to collect and transfer the shear forces of the diaphragm to the vertical uprights.

[0020] To further conserve space occupied by the vertical uprights, preferably the plurality of vertical uprights includes four vertical frame members arranged in a rectangular or square configuration to accommodate one or more grid cells such that one or more containers can be stacked between the four vertical frame members. By assembling the plurality of vertical uprights to accommodate or support one or more grid cells for storing one or more containers in one or more stacks, the vertical upright supporting the grid structure can double as a storage column for storing one or more containers in multiple stacks. Optionally, the four vertical frame members are configured to accommodate a single grid cell, such that the vertical upright provides a storage column for a single stack of containers. The four vertical frame members of the vertical upright can guide one or more containers stored between the four vertical frame members toward the grid structure. While not strictly necessary, this additional function of guiding vertical movement of containers can be advantageous in some instances. Optionally, at least two or pairs of the four vertical frame members are braced together by at least one diagonal brace member to provide structural integrity to the vertical uprights. Optionally, the braced vertical frame members form a vertical truss. The braced vertical frame members making up the vertical uprights provide increased structural support to the grid structure to resist lateral forces.

[0021] Since the container is lifted towards the grid structure by the lifting mechanism of the loading device, it is not necessary to engage or accommodate all four corners of the container along the vertical uprights. In another embodiment of the invention, a plurality of vertical uprights are arranged to support the grid or grid structure at alternating nodes in a first direction (e.g., x-direction) and a second direction (e.g., y-direction), and one or more containers are stacked between two of the vertical uprights and guided by the two vertical uprights. By supporting the grid structure at the alternate nodes or intersections, half the number of vertical uprights are required to support the grid structure. Furthermore, the grabber device and container are accommodated only in two corners with the vertical uprights. Preferably, the vertical uprights are arranged to engage a pair of diagonally opposed corners of the grabber device and container. That is, the grabber device and / or container are guided along their diagonally opposed corners. This provides a level of lateral stability for the grabber device and container in the X and Y directions as the container is lifted along the diagonally opposed vertical uprights.

[0022] In a further embodiment of the invention, the vertical uprights are braced together by at least one brace member extending from each of the vertical uprights to form a modular frame. For example, four vertical uprights can be braced together by at least one brace member extending from each of the four vertical uprights to form a modular box frame. Preferably, the grid structure is supported by one or more modular frames. That is, the grid structure can extend across multiple modular frames. Because the grid structure is supported by the modular frames, each of the one or more modular frames supports multiple grid cells, thereby providing a storage volume for storing multiple stacks of containers. Multiple modular frames can be assembled to create a larger storage volume than can be provided by a single modular frame. The modular frames are easily transportable and can be assembled to create a space for storing containers in a stack. For example, the modular frames can be container frames, such as shipping container frames. Preferably, the one or more modular frames are arranged in a stack such that the one or more stacks of containers extend through the one or more modular frames. Individual containers are stacked in vertical layers and their locations within the grid framework structure or "hive" may be indicated using three-dimensional coordinates to represent the location of the loading device or container and the depth of the container (e.g., (X,Y,Z), a container of depth W). Similarly, locations within the grid framework structure may be indicated in two dimensions to represent the location of the loading device or container and the depth of the container (e.g., (X,Y), a container of depth Z). For example, Z=1 identifies the top layer of the grid, i.e. the layer immediately below the rail system, Z=2 identifies the second layer below the rail system, and so on, the bottom layer, which is the bottom layer of the grid. Modular frames can be stacked on top of each other to increase the height of the grid framework structure, so the depth Z value can be increased.This allows the vertically stacked containers to be extended into one or more modular frames.

[0023] Emphasis is placed on strengthening the grid structure by using fewer vertical uprights to support the grid structure. In yet another embodiment of the invention, said grid structure comprises: i) an upper grid structure; ii) a lower grid structure, each of the upper and lower grid structures comprising a first set of grid members extending in a first direction and a second set of grid members extending in a second direction forming a plurality of grid cells, the upper grid structure being vertically spaced from the lower grid structure such that the grid cells of the upper grid structure are aligned with the grid cells of the lower grid structure; The upper grid structure and the lower grid structure are connected together by a plurality of diagonal and linear brace members to form a truss assembly.

[0024] To enable the grid structure to resist vertical and lateral forces as a result of one or more load-handling devices moving on it while remaining lightweight to provide a rigid structure, the grid structure may be formed from an assembly of trusses. The upper and lower grid structures connected to each other by a plurality of diagonal and linear bracing members may be considered as a truss assembly comprising a plurality of equally spaced parallel trusses in a horizontal plane. Each of the plurality of trusses may be considered to comprise an upper elongated truss member (upper chord) and a lower elongated truss member (lower chord) connected together by one or more diagonal braces and one or more linear vertical webs. The upper and lower elongated truss members form the top or top and bottom or bottom chords of the respective trusses. Under the weight of one or more load-handling devices operating on the grid structure, the upper chord is typically placed in compression and the bottom chord is typically placed in tension. The plurality of trusses are connected together in a parallel arrangement but separated or spaced apart by a plurality of linear horizontal upper cross webs between adjacent upper elongated truss members. Similarly, a plurality of straight horizontal lower cross webs connect between adjacent lower elongated truss members. The plurality of straight horizontal upper cross webs are substantially equally spaced or separated along the longitudinal length of the upper elongated truss member such that the upper elongated truss member and the plurality of straight horizontal upper cross webs connecting adjacent trusses together are arranged in a grid-like pattern to form a grid structure (upper grid structure) comprising a plurality of grid cells. Similarly, a plurality of straight horizontal lower cross webs are substantially equally spaced along the longitudinal length of the lower elongated truss member such that the lower elongated truss member and the plurality of straight horizontal lower cross webs connecting adjacent trusses together are arranged in a grid-like pattern to form a grid structure (lower grid structure) comprising a plurality of grid cells.

[0025] Preferably, the plurality of diagonal and linear brace members extend between opposing first or second sets of grid members in the upper and lower grid structures. Optionally, the plurality of diagonal brace members are arranged to form a K-brace between opposing first or second sets of grid members in the upper and lower grid structures. However, other brace assemblies are permissible in the present invention, including, but not limited to, an X-brace.

[0026] A plurality of tracks are preferably attached to the upper grid structure to allow one or more loading devices to move on the grid structure. Optionally, the first set of grid members comprises a first set of tracks and the second set of grid members comprises a second set of tracks. Optionally, the first set of grid members comprises a first set of track supports and the second set of grid members comprises a second set of track supports. Optionally, the first set of tracks are snap-fitted to the first set of track supports and the second set of tracks are snap-fitted to the second set of track supports of the upper grid structure. Also plausible in the present invention is that a plurality of tracks can be incorporated into the first and second sets of track supports such that the grid members of the upper grid structure comprise both tracks and track supports.

[0027] Optionally, the grid structure is made from a fiber reinforced composite material. In yet another option, the grid structure is made from a polymer material.

[0028] For purposes of all embodiments of the present invention, the grid member may comprise a track incorporated into the grid member, or, alternatively, the track may be a separate component from the grid member, with the track attached to the grid member. When the track is attached to the grid member, the grid member includes a track support, and the track is attached to the track support. For purposes of the present invention, the track may comprise either a single track or a dual track. A dual track allows two loading devices to pass side by side.

[0029] The present invention further provides a storage system comprising: i) the grid framework structure defined above; ii) multiple stacks of containers arranged under a grid structure, each occupying a single grid space or grid cell; iii) one or more load handling devices remotely operated to move one or more containers stored on the grid framework structure, each of the one or more load handling devices comprising: i) a wheel assembly for guiding the loading device on the grid structure; ii) a container receiving space disposed above the grid structure; and and iii) a lifting device arranged to lift a single container from the stack into the container receiving space.

[0030] Preferably, the lifting device includes a lifting drive assembly, a grabber device configured in use to releasably grasp a container and lift the container from the stack into the container receiving space, and a drive mechanism operably arranged to move the handling device on the grid structure.

[0031] Optionally, the body of the load handling device may include a cantilever as taught in WO2019 / 238702 (Autostore Technology AS), where the container receiving space is located below the cantilever of the load handling device, where the grabber device is lifted by the cantilever such that the grabber device can engage and lift a container from the stack into the container receiving space below the cantilever.

[0032] Further features of the present invention will become apparent from the following detailed description when considered in conjunction with the drawings.

[0033] Additional features and aspects of the present invention will become apparent from the following detailed description of illustrative embodiments that proceeds with reference to the drawings. [Brief description of the drawings]

[0034] [Figure 1] 1 is a schematic diagram of a grid framework structure according to known systems; [Diagram 2] FIG. 2 is a top-down schematic diagram showing a stack of bins arranged within the framework structure of FIG. 1. [Diagram 3] 1 is a schematic diagram of a known storage system for loading and unloading devices operating on a grid framework structure; [Figure 4] FIG. 2 is a schematic perspective view of the loading device showing the lifting device gripping the container from above. [Diagram 5] 5A is a schematic perspective cutaway view of the loading device of FIG. 4 showing a container accommodated within the container receiving space of the loading device; FIG. 5B is a schematic perspective cutaway view of the loading device of FIG. 4 showing the container receiving space of the loading device; [Figure 6] FIG. 1 is a plan view of a section of a known grid structure with four adjacent grid cells showing that the intersections or nodes of the grid members are supported by vertical uprights and each grid cell constitutes a storage column. [Figure 7]A perspective view showing four vertical uprights that make up a storage space or storage column within a grid framework structure. [Figure 8] FIG. 1 is a perspective view showing an arrangement of tracks and track supports interconnected at nodes or intersections by cap plates. [Figure 9] FIG. [Figure 10] FIG. 13 is a perspective view of a cap plate for interconnecting vertical uprights to grid members at nodes. [Figure 11] FIG. 13 is a perspective cross-sectional view of the interconnection of vertical uprights to grid members by cap plates at nodes. [Figure 12] FIG. 1 is a perspective view of a track or rail. [Figure 13] 1 is a perspective view of a storage system comprising a grid framework structure according to a first embodiment of the present invention; [Figure 14] 14 is a close-up of the grid structure of FIG. 13 at a node or intersection of the track supports, showing the tracks attached to the track supports. [Figure 15] 14 is a perspective view of an alternative embodiment of a grid structure of the grid framework structure shown in FIG. 13. [Figure 16] 16 is a close-up view of an intersection of the track supports of the grid structure of FIG. 15 showing the tracks attached to the track supports. [Figure 17] FIG. 13 is a perspective view showing the connection of track supports at nodes by slip joints. [Figure 18] FIG. 2 is a perspective view showing the arrangement of a stack of containers on a floor rail according to one embodiment of the present invention. [Figure 19] FIG. 2 is a perspective view of an example of a self-stacking container or storage bin according to one embodiment of the present invention. [Figure 20] FIG. 13 is a perspective view of cable guides at nodes or intersections of grid members for guiding movement of storage bins or containers within a stack. [Figure 21] 1 is a perspective view of a cable guide with a sleeve shaped to fit over the corner of a storage bin or container, according to one embodiment of the present invention; [Figure 22] FIG. 14 is a perspective view of an assembly of a plurality of modular units, each modular unit being the grid framework structure of FIG. 13; [Figure 23] FIG. 2 is a perspective view of a storage system comprising a grid framework structure according to a second embodiment of the present invention; [Figure 24] 24 is a plan view of a section of adjacent grid structures from two adjacent modular units, each modular unit comprising the grid framework structure of FIG. 23. [Diagram 25] FIG. 24 is a top view of a section of adjacent grid structures from four adjacent modular units, each modular unit comprising the grid framework structure of FIG. 23. [Figure 26] FIG. 1 is a perspective view of a section of a grid structure showing the linkages of the grid members for connecting to adjacent grid structures. [Figure 27] FIG. 13 is a perspective view of a storage system comprising a grid framework structure according to a third embodiment of the present invention. [Figure 28] 28 is a perspective view showing a section of a grid structure from adjacent modular units, each modular unit being the grid framework structure of FIG. 27; [Figure 29] FIG. 13 is a perspective view of a storage system including a grid framework structure according to a fourth embodiment of the present invention. [Diagram 30] FIG. 30 is a perspective view of the trusses that make up the grid structure shown in FIG. 29. [Diagram 31] FIG. 13 is a perspective view of a storage system comprising a grid framework structure comprising a plurality of container frames supporting a grid structure according to a fifth embodiment of the present invention. [Diagram 32] FIG. 1 is a perspective view of a stack of container frames forming a storage space for storing multiple stacks of containers. [Diagram 33]FIG. 13 is a perspective view of a section of a grid structure comprising four adjacent grid cells supported by five vertical uprights at alternate nodes in the x and y directions of a grid framework structure according to a sixth embodiment of the present invention. [Diagram 34] 34 is a perspective view of a section of a grid framework structure comprising the grid structure of FIG. 33; [Diagram 35] FIG. 34 is a perspective view showing the arrangement of vertical uprights supporting the grid structure of FIG. 33; [Diagram 36] FIG. 13 is a perspective view of a storage system including a grid framework structure according to a sixth embodiment of the present invention. [Figure 37] 1A and 1B are perspective views of an anchor foot for securing a vertical upright to a floor, according to one embodiment of the present invention; [Figure 38] FIG. 13 is a perspective view of a section of a grid framework structure according to a sixth embodiment of the invention, showing attachment of the grid structure to vertical uprights by an adjustable grid levelling mechanism. [Figure 39] 39 is a perspective view of a section of a grid framework structure showing tracks secured to track supports according to the embodiment of the invention shown in FIG. 38. [Diagram 40] 40A is a close-up view of the track connections at a node according to the embodiment shown in FIG. 39. [Diagram 41] 1A and 1B are perspective views of an adjustable grid leveling mechanism in accordance with one embodiment of the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] It is against the known features of storage systems such as the grid framework structures and material handling devices described above with reference to Figures 1 to 5 that the present invention has been devised. Figure 6 shows a top view of a section or portion of a conventional grid structure 40 comprising four adjacent grid cells 42 and 42, and Figure 7 shows a perspective side view of a single grid cell 42 supported by four vertical uprights 16 to form a single storage post 44 for storing one or more containers 10 in a stack. For purposes of the present invention, the term "adjacent" is taken to mean that each grid cell within a section of the grid structure 40 is immediately adjacent to one another within the section, either diagonally or laterally, as shown in Figure 6. For example, the term "adjacent" does not include a grid cell within a section that is not immediately adjacent to another grid cell within the section.

[0036] Each of the vertical uprights 16 is generally tubular. In a horizontal cross-section of the storage column 44 shown in FIG. 2, each of the vertical uprights 16 comprises a hollow central section 46 (typically a box section) and has one or more guides 48 attached or formed at the corners of the hollow central section 46, which extend along the longitudinal length of the vertical upright 16 for guiding the movement of containers along the storage column 44. The one or more guides 48 comprise two vertical container guide plates. The two vertical container guide plates are positioned to accommodate a corner of a container or a corner of a stack of containers. In other words, each of the corners of the hollow central section 46 defines two sides of a substantially triangular area that can accommodate a corner of a container or a storage bin. The corners are evenly spaced around the hollow central section 46 so that multiple vertical uprights 16 can provide multiple adjacent storage columns, and each vertical upright 16 can be common or shared for up to four separate storage columns. Also shown in FIG. 7, each of the vertical uprights 16 is attached to an adjustable grid leveling mechanism 19 at the foot of the vertical upright and includes a base and a threaded shaft that can extend or retract to compensate for uneven floors.

[0037] A horizontal cross-section of the storage columns 44 in FIG. 2 shows that each storage column 44 is made up of four vertical uprights 16 arranged at the corners of a container or storage bin 10. A storage column 44 corresponds to a single grid cell. The cross-section of the vertical uprights 16 is constant over the entire length of the vertical uprights. The perimeter of the container or storage bin in the horizontal plane of FIG. 2 shows a container or storage bin having four corners and the arrangement of the four vertical uprights 16 at the corners of the container or storage bin in the storage column 44. The corner sections of each of the four vertical uprights, one from each of the four vertical uprights, ensure that a container or storage bin stored in the storage column 44 is guided in the correct position relative to any containers or storage bins stored in the storage column and in the stack of containers or storage bins in the surrounding storage columns. A loading device (not shown) operating on the grid structure 40 can lift the container or storage bin as it is guided along the vertical uprights 16 through the grid cells 42. Thus, the conventional belief in the industry is that the vertical uprights 16 have a dual purpose: (a) to provide structural support for the grid structure 40, and (b) to guide the containers or storage bins 10 into position through their respective grid cells 42.

[0038] The top view of a section of the grid structure 40 shown in FIG. 6 shows a series of horizontal cross beams or grid members 18, 20 arranged to form a plurality of rectangular frames constituting the grid cells 42, more specifically a first set of grid members 18 extending in a first direction x and a second set of grid members 20 extending in a second direction y, the second set of grid members 20 extending transversely to the first set of grid members 18 in a substantially horizontal plane, i.e. the grid structure is expressed in Cartesian coordinates in the X and Y directions. The terms "vertical uprights", "uprights" and "uprights" are used interchangeably in the description. For the purposes of describing the present invention, the points or junctions where the grid members cross or intersect, indicated by the squares in FIG. 6, can be defined as nodes or intersections 50. It is clear from the layout of at least a portion or section of a known grid structure 40 constituting four adjacent grid cells 42 shown in FIG. 6, that each intersection or node 50 of the grid structure 40 is supported by a vertical upright 16. From the section or at least a portion of the grid structure 40 shown in FIG. 6, four adjacent grid cells are supported by nine vertical uprights 16, i.e., three sets of vertical uprights 16 supporting the grid structure in three rows, each row including three nodes 50.

[0039] Each of the grid members of the present invention may include a track support 18, 20 and / or a track or rail 22a, 22b (see FIG. 8), whereby the track or rail 22a, 22b is attached to the track support 18, 20. The loading device is operative to move along the track or rail 22a, 22b of the present invention. Alternatively, the track 18, 20 may be incorporated into the track support 18, 20 as a unitary body, for example by extrusion. In a particular embodiment of the present invention, the grid member includes the track support 18, 20 and / or the track 22a, 22b, whereby the track or rail 22a, 22b is attached to the track support 18, 20. At least one grid member in the set, for example a single grid member, may be subdivided or divided into separate grid elements that may be joined or connected together to form the grid member 18, 20 extending in a first direction or a second direction. When the grid member includes a track support, the track support may also be subdivided into separate track support elements that are connected together to form the track support. The separate track support elements making up the first and second axially extending track supports are shown in Figure 8. The individual track support elements 56 used to make up the track supports 18, 20 are shown in Figure 9. The track supports 18, 20 in cross section can be solid supports of C-shaped or U-shaped or I-shaped cross section, or even double C or double U-shaped supports. In a particular embodiment of the invention, the track support element 56 comprises double back-to-back C-sections bolted together.

[0040] A connecting plate or cap plate 58, shown in FIG. 8, can be used to link or join individual track support elements 56 in both the first and second directions at the junctions where multiple track support elements intersect within the grid structure 40. That is, the cap plate 58 is used to connect the track support elements 56 together to the vertical uprights 16. As a result, the vertical uprights 16 are interconnected at their top ends at the junctions where multiple track support elements intersect within the grid structure 40 by the cap plate 58. That is, the cap plate is disposed at the node 50 of the grid structure 40. As shown in FIG. 10, the cap plate 58 is cross-shaped with four connecting portions 60 for connecting to the ends or anywhere along the length of the track support elements 56 at the junctions 50. The interconnection of the track support elements to the vertical uprights at the nodes by the cap plate 58 is illustrated in the cross-sectional view of the node 50 shown in FIG. 11. The cap plate 58 includes a spigot or protrusion 62 sized to fit snugly into the hollow central section 46 of the vertical uprights 16 to interconnect the plurality of vertical uprights 16 to the track support elements, as shown in FIG. 11. Also shown in FIG. 11 are track support elements 56a, 56b extending in both vertical directions corresponding to a first direction (x-direction) and a second direction (y-direction). A connecting portion 60 is perpendicular to each other and connects the track support elements 56a, 56b extending in the first direction and the second direction. The cap plate 58 is configured to be bolted to the ends of the track support elements 56a, 56b or along the length of the track support elements. Each of the track support elements 56a, 56b are arranged to interlock with each other at nodes to form a grid structure 40 according to the present invention. To accomplish this, a distal or opposing end of each of the track support elements 56a, 56b includes a locking mechanism 64 for interconnecting with a corresponding locking mechanism 66 of an adjacent track support element.In certain embodiments of the invention, the opposing or distal ends of one or more track support elements include at least one hook or tang 64 receivable into an opening or slot 66 intermediate adjacent track support elements 56 at a junction where the track support elements intersect within the grid structure 40. Referring again to FIG. 9 in conjunction with FIG. 11, it is shown that the hook 64 at the end of the track support element 56 is received into an opening 66 of an adjacent track support element that extends across the vertical uprights 16 at a junction where the track support elements 56 intersect. Here, the hook 64 is provided up to the opening 66 on either side of the track support element 56b. In certain embodiments of the invention, the opening 66 is intermediate along the length of the track support element 56 such that when assembled together, adjacent parallel track support elements 56 in the first and second directions are offset by at least one grid cell. This is shown in FIG. 8.

[0041] To complete the grid structure 40, the tracks 22a, 22b are attached to the track support elements 56 once the track support elements 56 are interconnected to form a grid pattern with the track supports 18 extending in a first direction and the track supports 20 extending in a second direction. The tracks 22a, 22b are fitted onto the track supports 18, 20 in a snap-fit ​​and / or slide-fit arrangement (see FIG. 8). As with the track supports of the present invention, the tracks comprise a first set of tracks 22a extending in a first direction and a second set of tracks 22b extending in a second direction, the first direction being perpendicular to the second direction. The first set of tracks 22a is subdivided into a plurality of track elements 68 in the first direction such that, when assembled, adjacent parallel track elements in the first direction are offset by at least one grid cell. Similarly, the second set of tracks 22b is subdivided into a plurality of track elements 68 in the second direction such that when assembled, adjacent track elements in the second direction are offset by at least one grid cell. This is shown in FIG. 8. An example of a single track element 68 is shown in FIG. 12. As with the track support elements, a plurality of track elements in the first and second directions are laid together to form tracks in both directions. The attachment of the track elements 68 to the track supports 18, 20 comprises an inverted U-shaped cross-sectional profile shaped to bear against or overlap the top of the track supports 18, 20. One or more lugs extending from each branch of the U-shaped profile engage the ends of the track supports 18, 20 in a snap-fit ​​arrangement. Similarly, it is more preferred in the present invention that the tracks 22a, 22b can be incorporated into the track supports 18, 20 rather than being separate components.

[0042] Conventional wisdom holds that in order to structurally support the grid structure 40 above ground, it is necessary to support the grid structure 40 by vertical uprights 16 at each of the nodes 50. The vertical uprights 16 are therefore held under compression by the weight of the grid structure 40 and one or more handling devices operating on the grid structure 40. Additionally, the vertical uprights 16 double as grabber devices 39 (see FIG. 4) and guides to guide the containers of the stack through their respective grid cells. However, the present invention goes against conventional wisdom and demonstrates that the vertical uprights 16 may be positioned to structurally support the grid structure 40 without the need to support the grid structure at every node or intersection 50 of the grid structure 40. These range from transferring the majority of the load-bearing capacity of the grid framework structure to the grid structure 40 rather than just the vertical uprights 16, to balancing the number of vertical uprights 16 required to provide the load-bearing capacity of the grid structure. In a broad aspect of the invention, the plurality of vertical uprights 16 are arranged such that a section or at least a portion of the grid structure comprising four adjacent grid cells 42 is supported by five or fewer vertical uprights 16. The vertical uprights 16 function as structural elements in compression to support the weight of the grid structure 40 and one or more load handling devices operating on the grid structure 40.

[0043] Below, different embodiments of the invention are described in which a number of vertical uprights 16 are arranged such that a section of the grid structure 40 comprising four adjacent grid cells 42 is supported by five or fewer vertical uprights 16.

[0044] Support for single vertical upright grid section In a first embodiment of the present invention of a storage system 100 shown in FIG. 13, the grid structure 140 is configured such that a corner section 102 of the grid structure 140 comprising four adjacent grid cells 42 is supported by a single vertical upright 116. This is demonstrated by the close-up view of the corner section 102 shown in FIG. 13. Although FIG. 13 shows the corner section 102 being supported by a single vertical upright 116 at a node or intersection 50 of the grid structure 140, the present invention is not limited to the corner section 102 of the grid structure 140 being supported at the node or intersection 50. The corner section 102 of the grid structure 140 may be supported along any portion of the corner section 102. For the purposes of the present invention, the term "support" is taken to encompass any form of mechanical connection between the vertical upright 116 and the grid structure 140 or at least a section of the grid structure 140.

[0045] The grid structure 140 is supported by four vertical uprights 116 at the corner sections 102 of the grid structure 140, which support the weight of one or more load handling devices 30 operating on the grid structure 140, and the vertical uprights 116 are made more substantial than conventional vertical uprights generally known in the art as described above with respect to Figs. 2 and 7. In a particular embodiment of the invention shown in Fig. 13, each vertical upright 116 may be an I-shaped or H-shaped solid support beam including opposing beam flanges. The vertical uprights 116 at the corner sections of the grid structure 140 may be considered as load-bearing beams that are placed in compression under the weight of the grid structure 140 and one or more load handling devices 30 operating on the grid structure 140. Other types of vertical uprights that function as load-bearing beams to support the grid structure at the corner sections of the grid structure are applicable to the present invention. These include, but are not limited to, load-bearing beams having cross-sectional shapes such as L-shaped (angle), C-shaped (channel), or tube.

[0046] In addition to using load-bearing beams as vertical uprights, multiple brace members 104, 106, shown in FIG. 13, are arranged around the perimeter of the grid structure 140 to form a single frame body. In the particular embodiment of the invention shown in FIG. 13, the grid structure 140 has a rectangular or square configuration with four corner sections 102. The grid structure 140 is supported by four vertical uprights 116 at each of the four corner sections 102 of the grid structure. Each of the four vertical uprights 116 at the corner sections are braced together by at least one horizontal brace member 104 that extends longitudinally from the top of the vertical uprights 116 at the corner sections 102 to form a perimeter brace structure 105 that surrounds or at least partially surrounds the perimeter of the grid structure 140. The horizontal brace members 104 provide structural support to the grid structure 140 around the perimeter of the grid structure. In a particular embodiment of the invention, the perimeter brace structure 105 is supported above the ground by four vertical uprights 116 at the corners of the perimeter brace structure, creating an open space below for storing one or more stacks of containers. Four horizontal brace members 104 are attached to the top ends of each of the four vertical uprights 116 so as to extend from each corner of the perimeter brace structure 105. Like the vertical uprights, the horizontal brace members 104 function as load-bearing beams extending between the vertical uprights and can be I- or H-beams or other cross-sectional shapes that provide load-bearing beams around the perimeter of the grid structure. These include, but are not limited to, load-bearing beams having cross-sectional shapes such as L (angle), C (channel), or tube. In the particular embodiment shown in FIG. 8, the horizontal brace members are I-beams.

[0047] The horizontal bracing member 104 can be assumed to represent an upper chord connecting two vertical uprights 116 at the top of the perimeter bracing structure 105. The bracing of at least two vertical uprights at their tops by at least one horizontal bracing member 104 forms at least one drag strut or collector, as is commonly known in the art. The drag strut or collector is where at least two vertical uprights are braced by a horizontal beam at the tops of the two vertical uprights, and functions to collect and transfer the shear forces of the diaphragm to the vertical uprights. Also, as shown in FIG. 13, the four vertical uprights 116 are placed at the four corners of the grid structure 140 to form a rectangular parallelepiped structure having a top surface and four sides. The collection of vertical uprights 116 at the corner sections of the grid structure, together with the perimeter bracing structure 105, forms an exoskeleton that supports the grid structure. The exoskeleton provides structural support to resist lateral forces experienced by the grid structure. That is, the exoskeleton forms a moment resisting frame. The exoskeleton together with the grid structure forms a grid framework structure according to one embodiment of the present invention.

[0048] In addition to at least one horizontal brace member 104 extending between the vertical uprights 116, at least one diagonal brace member 106 can be connected to the vertical uprights 116 to provide additional stability to the exoskeleton. The brace members 104, 106 extending between the vertical uprights 116 are designed to function in tension and compression similar to a truss. In a particular embodiment shown in FIG. 13, a first end of the diagonal brace member 106 is connected to a lower end of the first vertical upright 116 and a second end of the diagonal brace member is connected to an upper end of the second vertical upright 116 on one or more sides of the exoskeleton. In a particular embodiment of the invention, each side of the exoskeleton comprises at least one diagonal brace member extending between two vertical uprights. Two or more diagonal brace members can be placed between two vertical uprights to form a cross ("X") brace on one or more sides or faces of the exoskeleton. The brace members are fixedly connected to the vertical uprights by connections or joints commonly known in the art, including, but not limited to, welding or using suitable fasteners such as bolts or rivets or combinations thereof, commonly known in the art.

[0049] The removal of the vertical uprights at each of the intersections or nodes of the grid members means that there is no support at the intersections or nodes of the grid structure, compared to the support provided by conventional grid framework structures in the above-mentioned technology, where there are vertical uprights at each of the intersections of the grid members. The exoskeleton with the perimeter brace structure 105 supported by vertical uprights at the corners can resist the lateral forces experienced by the grid structure. However, in order to transfer most of the lateral forces to the exoskeleton and to compensate for the loss of support at each intersection of the grid structure, the grid members 118, 120 that make up the grid structure 140 are made more substantial than the grid members of the art. Compared to the grid structures of the grid framework structures of the art, which mostly comprise back-to-back C-sections bolted together, the grid members of the present invention can comprise I-beams or tubular beams. In practice, it is believed that the bolted back-to-back C-sections are too weak to be self-supporting alone. For the purposes of the present invention, the term "self-supporting" is interpreted to mean that four adjacent grid cells are supported by no more than five vertical uprights. FIG. 14 is an example in which the grid members 118, 120 of the grid structure 140 are T-beams having a T-shaped cross section with an upper beam flange, which can withstand loads from one or more load handling devices operating on the grid structure. Similar to the tracks described above, the tracks or rails 168 have engagement portions that allow them to simply snap into the beam flanges of the T-beams 118, 120. While T-beams provide excellent support in the vertical direction, in another example of the invention, the grid members may be fabricated largely from I-beams with opposing beam flanges connected by web, tubular or box section beams. As shown in FIG. 15, the tubular beams 118, 120 provide improved stiffness and strength compared to back-to-back C-sections and I-beams. As shown in FIG. 15, the tubular cross-sectional profile of the grid members provides resistance to bending moments in multiple directions. Thus, bending moments experienced by the grid structure may be transferred to the exoskeleton, which absorbs lateral forces to a large extent.The exterior surfaces of the tubular beams 118, 120 have indentations or recesses 119 extending along the longitudinal length of the opposing walls of the tubular beams to allow the tracks or rails 168 to be snap-fit ​​or slidably fitted into the tubular beams as shown in FIG. 16. That is, the track supports are incorporated into and form part of the grid members 118, 120. In both embodiments of the invention shown in FIG. 15 and FIG. 16, the term "grid member" is broadly defined as including the track supports and / or the tracks. The tracks may be incorporated into the track supports. For example, the profile of the tracks may be molded into the track supports.

[0050] Alternatively, separate track support elements can be attached directly to the grid members so that the tracks can be attached thereon. The track support elements provide a key that allows the track or rail to be securely attached to the grid members 118, 120. A plurality of track support elements are distributed on the grid members having a profile shaped to receive the tracks. Thus, compared to the grid members of the grid structures described above in which the track support elements are incorporated into the body of the grid members, the track support elements of the grid structures are separate from the grid members and can provide a key to secure the tracks. The tracks are attached to the grid members by a snap-fit ​​and / or slide-fit arrangement via the track support elements. The track support elements can be welded to the grid members. The grid framework structure of the present invention is not limited to the track support elements being separate components that are welded to the grid elements of the grid. The track support elements can be incorporated into the body of the tubular grid members. For example, the profile of the track support elements can be extruded as a unitary body with the grid members, or the profile of the grid members can be molded to include the track support elements.

[0051] In one aspect of the invention, the grid members 118, 120 are welded together at the intersections instead of being bolted together to provide a stronger and more durable joint than bolting alone can provide. Thus, lateral forces occurring in the grid structure are transferred as bending moments at the joints where the grid members intersect at each of the nodes 50. According to one aspect of the invention, the grid members at the intersections are rigidly connected to each other to form at least one Vierendeel truss. As is commonly known in the art, a Vierendeel truss includes cords separated by web members formed as a series of rectangular frames. The rectangular openings of the Vierendeel truss make it ideally suited for a material handling device that moves one or more containers stored under the truss. In other words, the grid of the invention functions as at least one Vierendeel truss assembly.

[0052] The entire grid structure 140 can be pre-assembled together before being attached or fastened to the perimeter bracing structure 105 and / or the vertical uprights. By pre-assembling the grid members 118, 120 together, health and safety aspects are mitigated as a result of welding the grid members together on-site, as the grid members can be welded remotely in a safer environment, for example the use of robotic welding. The pre-assembled grid structure can then be attached or fastened to the vertical uprights 116 at the corner sections 102 of the grid structure 140 on-site. Welding the grid members together on-site or in-situ can violate health and safety legislation due to exposure to welding fumes and fire hazards. Further details of the connection of the grid structure 140 to the vertical uprights 116 at the corner sections 102 are discussed below. Although the grid members 118, 120 are shown as tubular, other cross-sectional shapes with the necessary load-bearing characteristics to support one or more load-handling devices operating on the grid structure are applicable to the present invention. These include, but are not limited to, an I-shape, a box-shape, an L-shape, or a C-channel that includes opposing beam flanges connected by a web.

[0053] The grid structure in the particular embodiment shown in FIG. 13 is configured such that the intersecting grid members are enclosed within a linear outer frame forming the perimeter brace structure 105. The linear outer frame surrounding the intersecting grid members 118, 120 provides an area for the grid structure 140 to be attached or connected to the linear outer frame. Alternatively, the grid structure may be attached to a separate structural support base (not shown) with cross members extending between opposing horizontal brace members of the perimeter brace structure 105. A first set of cross members extends in a first direction and a second set of cross members extends in a second direction. The first direction and the second direction correspond to the orientation of the first set of grid members and the second set of grid members of the grid structure. The first set of cross members are distributed in the first direction under the grid structure such that the individual cross members are spaced apart in the second direction by one or more grid cells. Similarly, the second set of cross members are distributed across the grid structure in the second direction such that each cross member extending in the second direction is spaced apart in the first direction by one or more grid cells. In one example, the first set of cross members are spaced apart in the second direction by three grid cells across the grid structure and the second set of cross members are spaced apart in the first direction by a single grid cell across the grid structure. The first set of cross members and the second set of cross members provide a structural base necessary to support the grid structure mounted thereon. The cross members may be I-beams or other cross-sectional shapes necessary to resist bending moments of one or more loading devices operating on the grid structure. These include, but are not limited to, box sections, L-shapes or C-channels. The structural support base may be made to support a majority of the load and therefore resist bending moments of loading devices operating on the grid structure. As a result, the grid structure mounted thereon does not need to support the full weight of the load. That is, the load on the grid structure may be distributed between the structural support base supporting the grid structure and the grid structure itself.In this manner, grid members can be substantially reduced and can even be based on existing grid structure elements including back-to-back C-sections. In another embodiment of the invention shown in Figure 13, grid members 118, 120 around the perimeter of a grid structure 140 provide mounting surfaces for the grid structure 140 to be attached to a perimeter brace structure, and more specifically, the grid members overhang at the edges of the grid structure, thereby providing mounting surfaces for attachment to horizontal brace members 104. This is clearly shown in Figure 13.

[0054] A variety of structural joints or connectors may be used to secure the grid structure to the horizontal brace members and / or structural support base extending between the vertical uprights. These include, but are not limited to, welds, bolts and / or rivets. The structural joints or connectors may also include one or more slip joints 108 to provide relative movement or "slip" between any of the connections of the perimeter brace structure 105 and the grid structure, as shown in FIG. 17. The slip joints 108 provide slip when the connections between adjacent grid members 118, 120 exceed a predetermined load. This allows the joints or connectors to accommodate movement, for example, as a result of differential thermal expansion between adjacent grid members 118, 120 of the grid structure 140 and / or components of the perimeter brace structure. A variety of slip joints commonly known in the art are applicable to the present invention. For example, slip joints can be used to securely attach the grid structure and / or the structural support base to the perimeter brace structure, allowing the grid structure and / or the structural support base to move relative to the perimeter brace structure if the connection between the grid structure and / or the structural base and the horizontal brace members exceeds a predetermined load as a result of differential thermal expansion between their respective components. For example, one or more slots 111 can be provided in either the grid members 118, 120 or the horizontal brace members of the grid structure when the grid structure is joined to the perimeter brace structure by one or more bolts 112 such that the one or more bolts can move along the slots 111. The same slip joints can be applied between the grid structure and the perimeter brace structure and / or between the structural support base and the perimeter brace structure, allowing relative movement between the cross members and the brace members of the perimeter brace structure 105.

[0055] If the grid member is an I-beam, the web of the grid member may be provided with a set of slots that are arranged to align with a series of holes with the mating surface of the adjacent grid member at the node or intersection, as shown in FIG. 17. As is commonly known in the art, one or more bolts that connect the grid members together in the grid structure are tensioned to allow the bolts to move along the slots if the applied load exceeds a predetermined threshold as a result of thermal expansion. To control "slip" between the grid members of the grid structure at the node or intersection, slip joints may be as described in U.S. Pat. No. 10,400,468 (Scott Randall Beard), whereby a mounting plate 114 is interposed between adjacent grid members of the grid structure and / or between the grid members and the perimeter brace structure. The mounting plate 114 may be welded or fixedly attached to one face of the grid member. The mounting plate 114 is provided with a series of vertical slots 122 that align with corresponding holes in the connecting grid member 118 to allow the connecting grid member to move relative to the mounting plate at the node or intersection. A fastener arrangement of bolts, nuts, and optional washers are inserted into the slots and holes to connect the grid members together at the nodes or intersections and / or the grid structure to the perimeter brace structure via the mounting plate 114.

[0056] Shims (not shown) may be placed between the mounting plate 114 and the connecting grid members 118, 120 to control the coefficient of friction between them. The shims may include corresponding slots aligned with the slots in the mounting plate and the connecting grid members. When the bolts are allowed to move along the slots, the grid members at the nodes or intersections may move or slide relative to each other. When assembled, the tension of the bolts may be selected to work with the coefficient of friction of the shims. This allows relative movement between the mounting plate and the grid members above a pre-determined load, but prohibits the mounting plate from moving relative to the grid members when the load is less than a pre-selected value. The same slip joint may be applied to the joints between the grid structure and the perimeter brace structure 105 and / or any joints connecting the vertical uprights to the perimeter brace structure.

[0057] The grid structure 140 is elevated off the ground by attachment to vertical uprights to create an open storage space for storing multiple stacks of containers. Conventionally, as described above, the containers or storage bins in the stack are guided through their respective grid cells by the vertical uprights at each of the nodes or intersections of the grid members. Removal of the vertical uprights means that the containers are lifted and elevated through the grid cells in free space by a handling device operating on the grid structure. Applicant has learned that a set of lifting tethers or tapes 38 at the four corners of the grabber device 39 (see FIG. 5) provides sufficient lateral stability of the grabber device 39 and the containers attached thereto to lift the containers through the grid cells without impacting or disrupting adjacent containers being lifted from adjacent stacks of containers. As shown in FIG. 13 and FIG. 15, the stacks of containers or storage bins 10 are spaced apart sufficiently to prevent the storage bins or containers in adjacent stacks from impacting each other as they are lifted through their respective grid cells. To ensure that adjacent stacks of containers are sufficiently spaced apart within the storage space, one or more stacks of containers are placed on floor rails 124 arranged in a grid pattern including one or more grid cells 126, as shown in FIG. 18. The arrangement of the floor rails 124 ensures that the grid pattern comprising one or more grid cells 126 of the floor rails 124 aligns with one or more grid cells 42 of the grid structure 140 above. This is so that the stacks of containers can be placed on the floor rails 124 in the same grid pattern as the grid structure 140. The floor rails 124 thus enable one or more handling devices operating on the grid structure 140 to lower the containers or storage bins to the correct position within the storage space.

[0058] To facilitate stacking of the containers or storage bins in the correct position within the storage space, the containers or storage bins 110 may be modified with one or more interlocking features that cooperate with corresponding interlocking features of adjacent storage containers in the stack. For example, the interlocking features may include one or more locating pins or bosses 113 arranged to cooperate with correspondingly shaped recesses 115 of an adjacent container when placed on top of the stack. In the particular embodiment shown in FIG. 19, each of the containers or storage bins 110 includes side walls 117 and a bottom wall 119 arranged in the form of a box having an open end for receiving the goods or items to be stored. Each of the walls of the containers or storage bins is modified to include one or more locating pins 113 at the edge of the container 110 and corresponding recesses 115 at the base or bottom wall 119 of the container. The edge of the container including the one or more locating pins or bosses 113 is shaped to be received in a correspondingly shaped recess 115 in the bottom wall 119 of another container that is placed directly above the stack. Using the terminology describing the location of containers in the grid framework structure above, where the depth of a container in storage is described by a depth value Z, with Z=1 being the topmost tier, Z=2 being the tier below the topmost tier, and so on, with Z increasing towards the bottom tier. The locating pins 113 of the containers in the lower tier (higher Z value) are positioned to be received in the recesses 115 of the containers in the upper tier (lower Z value) when the top container is lowered vertically along the vertical axis by the handling device. The locating pins 113 of the bottom container and the recesses 115 of the top container help guide the containers into the correct vertical position within the stack. The locating pins and correspondingly shaped recesses also help vertically stabilize multiple containers in a stack.

[0059] Locating pins / recesses formed in the walls of each container or storage bin with the ability to hoist the grabber device at all four corners of the grabber device alleviates the need to provide additional guidance in the form of vertical uprights in positioning an individual container into a particular stack on a storage column. However, the ability to support the grid structure at the corner sections as shown in FIG. 13 eliminates the need to support the grid structure at each of the intersections or nodes, where the vertical uprights serve the dual purpose of supporting the grid structure at the intersections and guiding the container along the vertical uprights in the stack. Vertical uprights in the art, i.e., compression members, do not need to have the structural properties required to support the grid structure at the intersections or nodes, where the vertical uprights serve the dual purpose of supporting the grid structure at the intersections and guiding the container along the vertical uprights in the stack, while the support for the grid structure is transferred to the corner sections 102, to additionally guide the container or storage bin into the correct stack within the storage space.

[0060] In one aspect of the invention, cables or tethers (or guide tethers) 130 can be positioned to extend between one or more intersections or nodes 50 of the grid structure and the floor. The cables or tethers 130 can be tensioned, i.e., using pretensioners (not shown) as are commonly known in the art, to provide a surface for guiding the movement of containers or storage bins along the tethers or cables 130 to the correct position within the stack. FIG. 20 shows a perspective view of multiple cables or tethers 130 secured 132 at nodes or intersections 50 of a grid structure 140 to one or more anchor points 134 strategically placed on the ground or floor corresponding to the corners of the grid cells such that one or more containers are guided along the tethers to the correct position within the stack. In the particular embodiment of the invention shown in FIG. 20, a first end of the cables or guide tethers 130 is secured 132 to the grid member at the node 50 and a second end of the cables or guide tethers 130 is secured 134 to the point where the floor rails 124 intersect at the ground.

[0061] The tethers or cables 130 are tensioned sufficiently to provide a guide surface for the containers or storage bins to be lowered or raised vertically in the stack or through the grid cells in the correct position, thereby preventing the containers from colliding with each other as containers in adjacent stacks are raised or lowered. Guiding the containers vertically in the stack or through the grid cells is not limited to tethers that are fixed to the intersections or nodes of the grid cells, as the containers or storage bins may be guided along any contact surface or wall of the container or storage bin so that the container or storage bin may be positioned in the correct stack. For example, the container or storage bin may be guided along any side wall of the container or storage bin. Similar to the vertical uprights, a group of two or more tethers or cables 130 may be arranged to extend between the grid structure and the floor to create a single storage post for one or more containers or storage bins stored in the stack. Multiple tethers or cables 130 may be arranged to extend between the grid structure and the floor to create multiple storage posts. Each tether or cable 130 in the grid framework structure may be common to up to two or more separate storage posts, i.e., one or more tethers may be shared between adjacent storage posts. In Figure 20, four guide tethers are shown extending between the grid structure and the floor rails at the nodes of the grid structure to provide guide surfaces for four adjacent containers or storage bins. This is repeated at one or more nodes of the grid structure.

[0062] A variety of known fasteners may be used to secure the tether or cable to the grid structure and the ground or floor. These include, but are not limited to, hooks. Tensioners include, but are not limited to, spring-based tensioners commonly known in the art. The guide tether 130 can be any cable, including, but not limited to, steel cable, rope, and the like. The guide tether 130 can include a sleeve 130a or be coated with a polymeric material to facilitate movement of the container or storage container along the guide tether and minimize wear on the container or storage bin, can be constructed mostly of plastic, or the guide tether can be worn. The sleeve 130a can be molded to accommodate the corner sections of the container or storage bin. In a particular embodiment of the invention shown in FIG. 21, the sleeve 130a is molded to include two vertical bin guide plates to accommodate the corners of the storage bin.

[0063] In assembling the grid framework structure of the present invention, the vertical uprights 116 are constructed in strategic locations braced by at least one brace member 104, 106 extending from the top end of each of the vertical uprights to create a perimeter brace structure around the grid structure 140. Additional brace members can extend between each of the vertical uprights 116. In the particular example of the present invention shown in FIG. 13, at least one diagonal brace member 106 extends between each of the vertical uprights 116. The grid structure 140 is attached to the perimeter brace structure and / or the vertical uprights. Optionally, guide tethers 130 can be secured to the grid structure 140 and to the floor or floor rails 124 in strategic locations to guide the movement of the containers to the correct position within the stack.

[0064] The grid framework structure of the present invention, supported by five or fewer vertical uprights (in this case a single vertical upright at each of the corner sections of the grid structure) as compared to having a vertical upright at each of the intersections or nodes of the grid structure, significantly reduces the processing steps required to construct the grid framework structure, which are largely absorbed by the time it takes to construct the vertical uprights at each of the intersections or nodes of the grid structure.

[0065] The grid framework structure shown in FIG. 13 can form part of a modular unit 100. Multiple modular units 100 can be assembled together to create a larger storage space for storing multiple stacks of containers. That is, the storage space of a modular unit can be expanded to multiple modular units. The vertical uprights 116 and perimeter brace structure 105 can be shared between adjacent modular units such that at least one common horizontal brace member 104 is shared with adjacent or neighboring modular units. This can be shown in the schematic diagram of the assembly of multiple modular units shown in FIG. 22. The grid structure 140 can be arranged to extend across multiple modular units such that the grid structure extends across the perimeter brace structure shared with adjacent or neighboring modular units while still supporting corner sections of the grid structure, the corner sections comprising four adjacent grid cells in each modular unit supported by five or less vertical uprights. However, a drawback of this arrangement is that maximum storage space is not achieved due to the perimeter brace structure 105 between adjacent modular units; in particular, the horizontal brace members 104 take up a portion of the grid structure that extends between adjacent modular units, i.e., taking up useful storage space. In the particular embodiment shown in FIG. 22, a column of grid cells, and therefore valuable storage space, is lost as a result of the horizontal brace members 104 extending between the vertical uprights at the junctures between adjacent modular units.

[0066] In another embodiment of the invention, to overcome this drawback between adjacent or neighboring modular units impinging on one or more grid cells, each of the vertical uprights 216 may be configured to occupy one or more storage posts such that one or more containers in the stack may be stored within the vertical uprights 216. In the particular embodiment of the storage system 200 shown in FIG. 23, each of the vertical uprights 216 is configured to occupy a single storage post. Thus, the vertical uprights 216 have the dual purpose of providing structural support to the grid structure 240 as well as the ability to provide a storage post for storing one or more containers in the stack. This prevents the vertical uprights and horizontal brace members from occupying valuable storage space that could be used to store containers in the stack below the grid structure. In the particular embodiment shown in FIG. 23, each of the vertical uprights 216 comprises a collection of truss members 219 arranged in a square configuration having a cross-sectional shape corresponding to a single grid cell. More specifically, each of the vertical uprights 216 comprises four vertical frame members 220 arranged in a square or rectangular configuration braced by one or more diagonal bracing members 222. The top of the vertical uprights 216 includes straight members 224 extending from each of the four vertical frame members 220 and arranged in a square or rectangular configuration to provide a surface for mounting a grid structure 240 at the corner section. The square or rectangular configuration corresponds to a single grid cell such that a grid structure may be attached to the vertical uprights or the vertical uprights may be incorporated into the corner section of the grid structure to accommodate a single grid cell. However, the present invention is not limited to four vertical frame members 220 arranged to correspond to a single grid cell at the corner section, and the vertical uprights 216 may similarly be arranged to occupy one or more grid cells.

[0067] In a particular embodiment of the invention shown in FIG. 23, the grid structure is attached to the vertical uprights 216 at the corner sections of the grid structure such that a single grid cell at the corner section of the grid structure overlaps the square or linear configuration of the vertical uprights 216. That is, a corner section of the grid structure constituting a single grid cell overlaps a single storage post of the vertical uprights 216. Thus, a handling device operating on the grid structure at the corner section can lower a container or storage bin through the grid cell and into the vertical uprights 216 where it is stored in a stack. The advantage of configuring the vertical uprights to include a single storage post for storing one or more containers in a stack is that it not only reduces the operations required to assemble the grid framework structure, but also that adjacent grid framework structures may be assembled together without affecting the storage capacity of the complete assembly.

[0068] The grid framework structure shown in FIG. 23 can form a single modular unit 200. Multiple modular units can be assembled to create a larger storage space for storing multiple stacks of containers under the extended grid structure. That is, the storage space of one modular unit can be extended to multiple adjacent modular units. Also, as shown in FIG. 23, only a portion 242 of the grid cells of the corner section is supported by at least a portion of the vertical uprights 216. The grid cells of the corner section are completed by another portion of the grid cells from the adjacent modular unit. Thus, the vertical uprights 216 of the corner section support only a portion of the grid cells. This percentage can be half of the grid cells 242a, 242b, or even a quarter of the grid cells 242a, 242b, 242c, 242d. The smaller the percentage supported by the vertical uprights at the corners of the grid structure, the more modular units from adjacent or neighboring modular units can share a common vertical upright. This allows multiple modular units to be assembled to complete a grid cell with vertical uprights. This is demonstrated by the various assembly options shown in Figures 24 and 25. Figures 24 and 25 show top views of corner sections of multiple adjacent or adjacent modular units.

[0069] In FIG. 24, the grid cell proportion at the corner section is half 242a, 242b such that grid structures 240a, 240b from two modular units share a common vertical upright. In FIG. 25, the grid cell proportion at the corner section is quarter 242a, 242b, 242c, 242d such that grid structures 240a, 240b, 240c, 240d from four modular units share a common vertical upright. The linkages joining adjacent grid structures from adjacent modular units together can include, but are not limited to, welds, bolts, and / or rivets. The linkages joining adjacent grid structures from adjacent modular units together can include a connection plate 244 that mates with a corresponding connection plate 244 of an adjacent grid structure to complete a grid cell or at least a portion of a grid cell depending on whether the proportion is half a grid cell or a quarter of a grid cell. 26, the connecting plate 244 extends from the grid members 118, 120, is oriented with the largest surface area lying perpendicular to the horizontal plane in which the grid lies, and includes one or more holes for receiving bolts. When adjacent grid structures are brought together, their corresponding connecting plates 244 come together to complete a grid cell or at least a portion of a grid cell. Multiple grid structures 240 from adjacent modular units can be joined together to form an extended grid structure according to one embodiment of the present invention.

[0070] In yet another embodiment of the invention, the connection between the grid structure 340 and the vertical uprights 316 at the corner sections can be such that the square or linear configuration of the vertical uprights 316 forms a single grid cell at the corner of the grid structure 340, i.e., the grid structure 340 accommodates the square or linear configuration of the vertical uprights 316 at the corner of the grid structure 340. In other words, the square or linear configuration of the vertical uprights 316 can be incorporated into the grid pattern of the grid structure, especially at the corners of the grid structure. The same vertical uprights as described above with reference to FIG. 23 can be used, but the grid structure is attached to the side of the vertical uprights 316 rather than to the top of the vertical uprights. A notch 318 the size of a single grid cell is created at the corner of the grid structure 340 to accommodate the vertical uprights 316. This is demonstrated by the embodiment of the storage system 300 shown in FIG. 27. Grid cells missing from corner sections of the grid structure 340 can be connected to the sides of the vertical frame members 320 of the vertical uprights 316, completing the grid structure such that the square or rectilinear configuration of the vertical uprights 316 is flush with the surface of the grid structure. Thus, a loading and unloading device operating on the grid structure can move on the vertical uprights 316 and thus treat the vertical uprights as grid cells. Although the particular embodiment shown in FIG. 27 shows a vertical upright accommodating a single grid cell in a storage post, the vertical uprights can be sized to accommodate one or more grid cells. The grid members 318b, 320b around the perimeter of the grid structure 340 can be made more substantial and provide sufficient structural support for the connections to the vertical uprights 316, as compared to the grid members throughout the interior of the grid structure.

[0071] Similar to the embodiment shown in FIG. 23, the grid framework structure shown in FIG. 27 can form a single modular unit 300. Multiple modular units can be assembled to increase storage space. FIG. 28 shows a top view of a corner section of two adjacent or adjacent modular units 340a, 340b where a common vertical upright 316 is shared between the two modular units 340a, 340b at the corner section of the modular units 340a, 340b. To assemble adjacent or adjacent modular units together to expand storage space, one corner section of the modular unit 340a is missing a grid cell to accommodate the vertical upright 316. The adjacent or adjacent modular grid structure 340 can then be butted next to the modular unit that accommodates the vertical upright 316 to expand the grid structure and thus expand the storage space as shown in FIG. 28.

[0072] Similar to the embodiment described with reference to FIG. 23 above, a stack of containers is stored in an open space and thus guided through respective grid cells above by a handling device operating on the grid structure by releasably gripping the container below via a grabber device and lifting the container through the grid cell. The grabber device suspended by four lifting tethers at the corners of the grabber device helps to maintain the stability of the container as it is lifted by the lifting mechanism of the handling device. To provide further guidance to the container as it is lifted or lowered from the stack by the handling device, one or more guide tethers as described above can be secured to the grid structure and floor or floor rails at strategic locations and placed under tension to provide a guide surface for guiding the container as it is lifted or lowered by the handling device.

[0073] In both embodiments shown in Figures 23 and 27, the grid members support the weight of one or more load handling devices operating on the grid structure 240, 340. Here, the grid members are primarily load bearing and therefore include load bearing beams such as I-beams or other cross-sectional shapes that can provide load bearing beams as known in the art. These include, but are not limited to, load bearing beams having cross-sectional shapes such as L (angle), C (channel), or tube or box sections. In the particular embodiment shown in Figure 27, the grid members are I-beams. As previously mentioned, the grid members can be welded at the intersections instead of bolted to provide stiffer and stronger joints than can be provided by bolting alone. Thus, lateral forces generated in the grid structure are transferred as bending moments at the joints where the grid members intersect at each of the vertical uprights. According to one aspect of the invention, the grid members at the intersections are rigidly connected to each other to form at least one Vierendeel truss. As with the first embodiment of the invention described with reference to Figures 13 to 17, the term "grid members" is broadly defined as including track supports and / or tracks. The track may be incorporated into the track support, for example the profile of the track may be molded into the track support.

[0074] Assembling the grid framework structure requires constructing the vertical uprights and connecting or attaching the grid structure to the vertical uprights at the corner sections. The grid structure may be prefabricated or assembled together on-site. The elimination of the vertical uprights at each of the intersections or nodes significantly reduces the time to construct the grid framework structure of the present invention, and therefore reduces the cost. Bolts or other suitable attachment means may be used to fasten the diagonal braces to the uprights. The grid members may be manufactured from steel or other metallic materials.

[0075] Truss grid structure In contrast to having the grid members of the grid structure more substantial (in thickness and weight) to collectively support the weight and lateral forces experienced as a result of one or more loading devices operating on the grid structure, in yet another embodiment (fourth embodiment) of the present invention, the grid structure 440a may be supported on or formed from an assembly of trusses. The assembly of trusses provides a lightweight rigid structure including a triangular system of linearly interconnected structural elements in axial tension or compression. In a particular embodiment (fourth embodiment) of the storage system 400 shown in FIG. 29, the track 422 is supported on an assembly of Warren trusses with diagonal brace members joining the upper and lower chords or members. An example of the individual truss members or trusses 402 that make up the truss assembly is shown in FIG. 30. Although the particular embodiment shows a Warren truss assembly, the truss assembly can be any type of truss that provides structural rigidity to the grid framework structure against lateral forces, including, but not limited to, a Warren truss, a K truss, a Fink truss, a Pratt truss, a Gambrel truss, or a Howe truss. In a particular embodiment of the invention, a diagonal brace member 404 is placed between the upper chord 406 and the lower chord 408 to form a K-brace. The truss assembly can have a triangular or other non-trapezoidal shape. Other diagonal configurations are applicable, including, but not limited to, an X-brace between the upper and lower chords. During operation of the grid structure, the upper chord 406 is typically in compression and the lower chord 408 is typically in tension within the assembly. In addition to the diagonal brace members 404 connecting the upper chord 406 and the lower chord 408, a straight downward member or web 410 is placed between the upper chord 406 and the lower chord 408.

[0076] The assemblies of trusses are joined together laterally in a horizontal plane separated from one another by one or more straight cross members 412 extending in a first direction. The straight cross members 412 are fixedly connected between the top chords 406 of adjacent trusses 402. Optionally, straight cross members 414 are fixedly connected between the bottom chords 408 of adjacent trusses 402. The straight cross members 412 connecting the individual truss members 402 together are equally spaced along the longitudinal length of the truss members 402 extending in a second direction. The separation between the individual trusses 402 and the spacing of the straight cross members 412 connecting the individual truss members 402 together are arranged to create a grid pattern similar to that of the grid structure described above. That is, the first direction is substantially perpendicular to the second direction. In the particular embodiment of the invention shown in FIG. 29, the upper chords 406 of adjacent trusses 402 and the straight cross members 412 connecting the upper chords 406 together are arranged to provide an upper grid structure with a plurality of grid cells. Similarly, the lower chords 408 of adjacent trusses 402 and the straight cross members or lower straight cross members 414 connecting the lower chords to each other are arranged to provide a lower grid structure with a plurality of grid cells. To be consistent with the terminology used in other embodiments of the invention (first, second, and third embodiments of the invention), the grid structure in this embodiment of the invention includes an upper grid structure 440a and a lower grid structure 440b. The grid cells of the upper grid structure 440a and the grid cells of the lower grid structure 440b are aligned such that a grabber device from a load handling device 30 operating on the upper grid structure 440a can be lowered and / or raised through the grid cells of the upper grid structure 440a and the lower grid structure 440b. That is, the grid cells of the upper grid structure 440a and the lower grid structure 440b overlap vertically such that the respective grid cells are aligned.

[0077] The assembly of the upper chords 406 and the straight cross members 412 between adjacent trusses 402 are arranged in a grid pattern to provide a track support including a plurality of grid cells. Attached to the track supports are tracks 422 arranged in a similar grid pattern having a first set of tracks extending in a first direction and a second set of tracks extending in a second direction, the first direction being substantially perpendicular to the second direction. The track supports and tracks are arranged in a grid pattern to define a grid structure of the present invention. The plurality of tracks 422 include engagement features that can snap into corresponding engagement features on the track supports of the upper grid structure 440a. It is equally applicable to the present invention for the tracks 422 to be incorporated into the upper chords 406 and straight cross members 412 between adjacent trusses 402 so that one or more load handling devices 30 can travel on the upper grid structure 440a. For example, the profile of the upper chords 406 and straight cross members 412 between adjacent trusses 402 is shaped to provide the tracks 422. For purposes of the present invention, a track may include either a single track or a dual track.

[0078] The truss 402 assemblies are connected together to provide an upper grid structure 440a and a lower grid structure 440b. The truck support including the truss assemblies is elevated above the floor by being attached to four vertical uprights 416 at its corner sections to create an open storage space for storing the containers 10, 110. The truss assemblies are arranged in a square or rectilinear configuration supported by the four vertical uprights 416 at the corners of the truss assemblies. Similar to the embodiment shown in Figs. 13 to 28, the corner sections of the truss assemblies, and thus the grid structure 440a including four adjacent grid cells (e.g., at the upper and / or lower grid structures), are supported by a single vertical upright 416. This is repeated at all four corner sections of the truss assemblies. The vertical uprights 416 supporting the grid structure 440a at the corners of the grid structure may be braced by one or more diagonal 424 and / or straight horizontal bracing members 426. Straight horizontal brace members 426 bracing the tops of the vertical uprights 416 may correspond to the straight cross members 414 between adjacent trusses 402 .

[0079] In a particular embodiment shown in FIG. 29, the vertical uprights 416 are braced by X-braces on each side or face of the grid framework structure. To compensate for uneven floors, adjustable feet 428 are attached to the bottom ends of each of the vertical uprights 416. In a particular embodiment of the invention, the adjustable feet include threaded shafts that can be extended or contracted to adjust the height of the adjustable feet 428. The assembly of beams (chords) or elements 406, 408 that make up the truss 402 and straight cross members 412, 414 can be I-beams or beams of any other cross-sectional shape, such as box-shaped, L-shaped or C-shaped.

[0080] The advantage of the truss assembly over grid structures manufactured from heavy load-bearing beams described with reference to Figs. 13 to 28 is that it offers the opportunity to manufacture the grid structure from lightweight materials. The truss assembly may be fully or partially prefabricated before attachment to the vertical uprights on-site. The triangular system of linearly interconnected structural elements in axial tension or compression allows the use of various types of materials for the truss elements, including but not limited to steel, aluminum, or lighter materials such as plastic materials and composite materials, e.g., carbon fiber reinforced materials. Bolts or other suitable attachment means may be used to fasten the diagonal braces to the uprights. The use of composite or polymeric materials for the structural elements of the truss also allows the structural elements to be joined using special adhesives. The use of lightweight materials or beams that make up the truss elements or members 402 allows the grid structure 440a to be easily handled manually on-site without or with minimal use of heavy lifting machinery.

[0081] As with the other embodiments described above, the grid framework structure shown in FIG. 29 can form a modular unit 400. Multiple modular units can be assembled to create a larger storage space for storing multiple stacks of containers under the extended grid structure. That is, the storage space of one modular unit can be extended to multiple adjacent modular units. One or more vertical uprights can be shared between adjacent modular units. Similarly, as with other embodiments of the present invention, the containers in the stack are lifted through the grid cells by one or more handling devices operating on the grid structure. The grabber devices releasably engage with the containers 10 in the storage space to lift or lower the containers through the grid cells, i.e., through the lower 440b and upper 440a grid structures. As described above, one or more stacks of containers can be arranged on the floor in a regular grid pattern by floor rails, which allows one or more handling devices operating on the grid structure to lower the containers or storage bins to the correct positions in the storage space.

[0082] Similarly, as described above, a stack of containers stored in a storage space can be guided to the correct grid cells by guiding tethers held under tension at strategic locations between the grid structure, i.e., the lower grid structure 440b, and the floor or floor rails. The guide tethers can be arranged in a grid pattern that corresponds to the grid pattern of the grid structure.

[0083] Container Grid In yet another embodiment of the storage system 500 shown in FIG. 31 (a fifth embodiment of the present invention), a plurality of modular support unit frames or modular frames or an assembly of modular storage unit frames 502 are arranged together to support a grid structure 540, i.e., the grid structure 540 extends across or over the plurality of modular support unit frames 502. For purposes of the present invention, the terms "modular support unit frame", "modular storage unit frame", and "modular frame" are used interchangeably to mean the same feature. The grid structure can be a plurality of individual grid structures that can be joined or joined to create a single grid structure that extends across the plurality of modular support unit frames or module frames, or a single integrated grid structure that extends across the plurality of modular support unit frames or module frames. Each of the modular support unit frames 502 defines a storage volume or space when assembled together, providing storage for multiple stacks of containers. In this manner, each of the multiple modular support unit frames 502 may be easily transportable and assembled together to create a storage frame 501 that defines a larger storage volume for storing multiple stacks of containers than may be provided by the individual modular support unit frames alone. Assembly of the modular support unit frames 502 includes, but is not limited to, stacking the modular support unit frames 502, assembling them side-by-side, or a combination of both. A grid structure is attached to the multiple modular support unit frames 502 depending on whether the multiple modular support unit frames 502 are arranged side-by-side or in a stack. When the multiple modular support unit frames 502 are arranged side-by-side, the grid structure attached thereto extends across the multiple modular support unit frames 502.When multiple modular support unit frames 502 are arranged in a stack, the grid structure extends across one of the multiple modular support unit frames 502 at the top of the stack, allowing the storage volume of the arrangement to extend vertically through the stack.

[0084] Each of the modular support unit frames 502 includes four vertical uprights 516 braced together by straight cross or horizontal members 504 and, optionally, diagonal bracing members 506 to form a 3D box frame such that when supporting the grid structure 540, a corner section of the grid structure 540 including four adjacent grid cells is supported by the vertical uprights 516 of a single modular support unit frame 502. In a particular embodiment of the present invention, the modular support unit frames 502 are preferably manufactured as container frames having dimensions of a shipping container, also known as a shipping container frame. The shape and size of the modular support unit frames 502 allow the modular support unit frames 502 to be transported and assembled on-site. For example, manufacturing the modular support unit frames 502 to resemble the dimensions of an open shipping container frame allows the modular support unit frames 502 to be transported to a desired location on the back of a truck. Each of the modular support unit frames 502 shown in FIG. 31 is sized to accommodate a plurality or multiple grid cells and therefore store multiple stacks of containers.

[0085] In a particular embodiment of the invention shown in FIG. 31, a plurality of modular support unit frames 502 are assembled together in a stack to create a storage frame 501 for mounting a grid structure 540 having a defined storage volume extending through the plurality of modular support unit frames 502. The modular support unit frames 502 house or provide a storage volume or space for storing a plurality of stacks of containers 10. The storage volume or space may be expanded through a stack of modular support unit frames 502 or an assembly of one or more modular support unit frames 502 such that the height of a stack of a plurality of containers 10 extends through one or more of the modular support unit frames 502. In a particular embodiment of the invention shown in FIG. 31, the storage volume defined by the storage frame 501 is comprised of an assembly of 3×2×2 modular support unit frames 502 (3 modular support unit frames high, 2 modular support unit frames wide, 2 modular support frames deep). However, the storage volume or space may include any arrangement of modular support unit frames 502 assembled together in stacks and / or side-by-sides. The assemblies of modular support unit frames 502 may be connected or coupled together using various coupling members or connecting plates to create a stable base for mounting the grid structure 540.

[0086] Each of the individual modular support unit frames 502 includes a top frame, a bottom frame, and side frames that are pre-assembled together prior to delivery to the site, for example, by welding the frames together. The individual modular support unit frames within the assembly are precisely aligned with each other using various coupling arrangements known in the art. For example, various pins can be used to precisely align the individual modular support unit frames together within the storage frame 501. Alternatively, the individual modular support unit frames can be flat packed for delivery and then assembled together at the site. Various means of flat packing the modular support unit frames 502 known in the art are applicable to the present invention. For example, the top and bottom frames can be shipped separately and connected with vertical uprights at the corners of the top and bottom frames.

[0087] The grid structure 540, including the track supports, is attached to the assembly of the modular support unit frames 502 and secured to the assembly by any fasteners known in the art, including but not limited to welding, bolts, and the like. The grid structure 540 is attached to the assembly of the modular support unit frames 502 such that a corner section of the grid structure, including four adjacent grid cells, is supported by a single vertical upright 516. To accommodate differential thermal expansion between the grid structure and the storage frame, the joints connecting the grid structure 540 to the modular support unit frames may also include the slip joints mentioned above that allow the joints to move when the load exceeds a predetermined value. One or more load handling devices 30 operating on the grid structure 540 may access containers in a stack housed within one or more of the modular support unit frames 502. For example, the load handling device 30 operating on the grid structure may retrieve a container housed within a stack of the modular support unit frames 502.

[0088] The containers 10 are guided through their respective grid cells by grabber devices that engage the containers below and lift the containers through the grid cells. As described above, one or more guide tethers can be tensioned and extend vertically between one or more modular storage unit frames 502 in the stack and the floor to provide a surface for guiding the containers towards the correct grid cells. The guide tethers can be tensioned between the grid structure above and the floor to create storage columns. Additionally, floor rails as described above can be laid on the floor to assist in proper alignment or positioning of the containers so that the stack of containers is properly spaced within the storage space.

[0089] 32 shows an example of a storage frame 501 including a single stack of three container-sized modular support unit frames 502a, 502b, 502c supporting a grid structure 540 including 7×4 grid cells, i.e., each of the modular support unit frames 502a, 502b, 502c is sized to accommodate a 7×4 grid cell. The bottom or lower modular support unit frame 502c includes adjustable leveling feet (not shown) at each corner of the modular support unit frame 502c to adjust the level of the stack of modular support unit frames 502a, 502b, 502c, and thus the upper grid structure 540. For example, the corner feet of the bottom or lower modular support unit frame 502c can be provided with adjustable feet (not shown) having extendable threaded shafts to compensate for uneven floors.

[0090] The intermediate modular support unit frame 502b, which is interposed between the upper modular support unit frame 502a and the lower modular support unit frame 502c, is connected between the upper modular support unit frame 502a and the lower modular support unit frame 502c by one or more fasteners, e.g., fastener plates. The upper modular support unit frame 502a supports a grid structure 540 including a plurality of grid cells. The grid structure 540 is attached and secured to the upper modular support unit frame 502a, e.g., by welding. The grid structure 540 with tracks or rails can be pre-attached to the upper modular support unit frame 502a before delivery to the site. The pre-assembled container frame or modular support unit frames 502a, 502b, 502c provide an assembly that helps to assemble the modular support unit frames on-site to create a grid framework structure that is constructed much more quickly than current technology. The mere fact that the containers or storage bins 10 may be guided by a grid structure or loading device 30 operating on a truck 540 eliminates the need to provide vertical support uprights at each of the nodes or intersections of the grid members, so that individual modular support unit frames 502a, 502b, 502c can be transported to the site on the back of a vehicle. A lifting crane can be used to lift and position the individual containers 502a, 502b, 502c at the site where they are assembled and joined together to create expanded storage space for storing one or more containers in a stack.

[0091] A grid structure 540, including tracks or rails for loading devices to travel on, is attached to the assembly of modular support units 502a, 502b, 502c. The ability to pre-assemble the storage space and attach the grid structure 540 on top allows the grid framework structure of the present invention to be assembled on-site within a day or two.

[0092] Half of the leg grid The realization that few or no physical guides are required to guide a container through each grid cell allows, in yet another embodiment of the invention, the number of vertical uprights in the storage column shown in Figure 7 to be reduced so that a container or storage bin is guided along two or a pair of diagonally opposite corners or edges of the container or storage bin. Compared to the known corner section of a grid structure with four adjacent grid cells as shown in Figure 6, where the grid structure is supported by a vertical upright at each of the nodes or intersections of the grid members, in a particular embodiment of the invention shown in Figure 33 (a sixth embodiment of the invention), the grid structure 640 is supported by half the number of vertical uprights 616 so that a container or storage bin is guided along two or a pair of diagonally opposite corners or edges of the container or storage bin, i.e., four adjacent grid cells are supported by five vertical uprights instead of nine vertical uprights. Thus, the individual storage post 644 shown in FIG. 34 comprises only two vertical uprights 616 instead of four vertical uprights for engaging two corners or edges of a container or storage bin in the storage post. Similar to vertical uprights in the art, each of the vertical uprights comprises a hollow central section (typically a box section) and has one or more guides attached to or formed at the corners of the hollow central section, which extend along the longitudinal length of the vertical upright for guiding the movement of the container along the storage post. The one or more guides comprise two vertical container guide plates. The two vertical container guide plates are positioned to accommodate the corners of a container or a corner of a stack of containers. In other words, each of the corners of the hollow central section defines two sides of a substantially triangular area that can accommodate the corners of a container or a storage bin. The vertical uprights 616 are arranged in a grid structure 640 of the sixth embodiment of the present invention such that one or more containers in a stack are guided only by two diagonally opposed vertical uprights 616.As a result, as shown in the top view of the grid structure in FIG. 33, a corner section of the grid structure 640 comprising four adjacent grid cells is supported by five vertical uprights 616, as opposed to nine vertical uprights as shown in FIG.

[0093] Typically, two different lengths of grid members allow the grid members to be arranged to form a number of rectangular grid cells that accommodate rectangular cross-sectional shaped containers or storage bins. To create an arrangement that halves the number of vertical uprights in a grid framework structure, alternate nodes or intersections 50 of the grid structure in two vertical directions are supported by vertical uprights 616, and the grid structure 640 is comprised of grid members of two or more different lengths, as opposed to a single length of grid member that covers the entire grid structure. In a particular embodiment of the invention shown in Figures 33 and 34, four different lengths of grid members 618a, 618b, 620a, 620b are arranged to form a number of rectangular grid cells. Although not shown to scale, the arrangement of the grid members creates a pattern in which half the number of nodes or intersections are supported by vertical uprights. As can be made clear in Figure 33, the longer grid members 618a, 620a, represented by patterned lines, extend across at least two grid cells, and the shorter grid members 618b, 620b, represented by different patterned lines, extend across a single grid cell. The longer grid members 618a, 620a that extend across at least two grid cells provide the necessary support to eliminate the need to support the nodes or nodes with vertical uprights at one or more points or junctions intermediate the ends of the longer grid members 618a, 620a. Thus, the loads experienced by the at least one node or node that is not supported by a vertical upright are carried by the grid members 618a, 620a that extend across at least two grid cells.

[0094] The section of the grid structure with four adjacent grid cells shown in FIG. 34 includes a first grid member 618a having a first length that extends across four grid cells in a first direction (e.g., x-direction), a second grid member 620a having a second length that extends across four grid cells in a second direction (e.g., y-direction), a third grid member 618b having a third length that extends across two grid cells extending in the first direction, and a fourth grid member 620b having a fourth length that extends across a single grid cell in the second direction. Although the particular example shown in FIG. 34 shows four different lengths of grid members, supporting the grid structure at alternative nodes or intersections can utilize any number of grid members of different lengths, such that at least one length extends across two or more grid cells. Using grid members of two or more different lengths can allow the longer grid members to extend across two or more grid cells, eliminating the need to support the grid members with vertical uprights at every intersection or node between two or more grid cells. The grid members 618a, 620a, 618b, 620b of different lengths are arranged in a grid pattern with equal sized grid cells such that the longer grid members extend across two or more grid cells and the shortest grid members extend across a single grid cell. The longer ones of the grid members 618a, 620a are staggered within the grid structure such that they are offset by at least two grid cells in both the first and second directions.

[0095] To join the individual grid members 618a, 620a, 618b, 620b together at the nodes or intersections, various fasteners known in the art may be used and will depend largely on the cross-sectional shape of the grid members. These include, but are not limited to, bolts, rivets, or welds. The grid members may be back-to-back C-sections as described above with reference to Figures 8 and 9. However, to provide the necessary structural support, the grid members are preferably I-beams as shown in Figure 34, or other cross-sectional shapes that provide the necessary structural support for the grid structure to support one or more loading devices operating on the grid structure and are permissible in the present invention. In the particular embodiment shown in Figure 35, the cap plate 58 described above may be used to interconnect the grid members to one another at the nodes or intersections 50. The grid members include track supports 618, 620 and / or tracks 622, which are attached to the track supports 618, 620. The track supports may be incorporated into or form part of the grid members such that the tracks can be attached to the track supports. For example, if the cross-sectional profile of the track supports 618, 620 is an I-beam, the underside of the track 622 is shaped to bear against a beam flange of the I-beam and engage the track support in a snap-fit ​​arrangement. Alternatively, the track can be incorporated into the track support such that the grid member comprises both the track support and the track.

[0096] Compared to the prior art, where each storage post includes a group of four vertical uprights arranged in a grid-like pattern, as shown in FIG. 6, in a particular embodiment of the present invention shown in FIG. 33, each storage post 644 includes two vertical uprights 616 arranged in a pattern such that diagonally opposite corners or edges of a container or storage bin are accommodated by only two vertical uprights 616. Thus, where each of the four vertical uprights of a given storage post are shared with an adjacent storage post, in a particular embodiment of the present invention, only two vertical uprights 616 are shared with the adjacent storage post. A single stack of containers 10 is shown in FIG. 35 stored along diagonally opposite corners of the stack. Having the ability to guide containers or storage bins into position through the grid cells by guiding containers only along diagonally opposite corners or edges while reducing the number of vertical uprights reduces the time and cost of building a grid framework structure. Additionally, the grid structure 640 only needs to be supported in the X and Y directions at alternate nodes or intersections 50, rather than at every node or intersection. The arrangement of the stack of containers under the grid structure remains the same, but is guided only along two edges or corners of the containers. This is demonstrated in the storage system 600 shown in FIG. 36. In the grid framework structure shown in FIG. 36, it is clear that not all of the nodes or intersections of the grid members are supported by the vertical uprights 616. Using the grid member orientation terminology discussed above with reference to FIG. 1, alternate nodes or intersections of the grid members in a first orientation are supported by vertical uprights. Similarly, alternate nodes or intersections of the grid members in a second orientation are supported by vertical uprights. The first and second orientations may represent the X and Y directions of the grid structure.

[0097] Grid Level In all of the embodiments shown in Figs. 13 to 36, an adjustable foot (not shown) with a telescopic threaded shaft can be optionally provided at each of the vertical uprights or at the attachment between the vertical uprights and the grid structure to compensate for uneven floors. In a preferred embodiment of the present invention, the lower end of one or more vertical uprights of the grid framework structure is fixed to the floor, e.g., a concrete foundation, by an anchor foot. The anchor foot is fixed to the floor by one or more anchor bolts. Various types of fixing feet for firmly fixing the vertical uprights to the floor are applicable to the present invention. The anchor foot functions to support the load of the vertical uprights and the brace load of the vertical uprights. An example of an anchor foot 700 is shown in Fig. 37, which is an example of an anchor foot 700 whose topology is optimized within given physical constraints based on the loads experienced at the base of the vertical uprights. In a particular embodiment of the invention shown in Figures 37(a and b), an anchor foot 700 has two anchor points 702 for bolting the anchor foot 700 to a floor or concrete foundation, and an opening 704 for receiving the lower end of a vertical upright 716 which is then inserted into the opening 704. The lower end of the vertical upright 716 is secured to the anchor foot 700 by two additional bolts 706 (see Figure 37b).

[0098] With one or more handling devices operating on the grid structure, it is of utmost importance that the grid structure be in a substantially horizontal plane, as this will affect the direction in which the container or storage bin is hoisted through the grid cells into the correct position. If the level of the grid structure is misaligned from the horizontal plane, not only will it put strain on the handling device or devices moving on the grid structure, but depending on the direction of the misalignment, it may also cause the lifting tethers to swing to one side and, in the worst case, cause the grabber device to not engage the container or storage bin below. The problem is exacerbated if the floor on which the grid framework structure is installed is not flat. This problem is especially exacerbated when the grabber devices and containers are not guided by vertical uprights as in the present invention, i.e., when stacks of containers are stored in free space. Conventionally, the level of a grid structure attached to a vertical upright is adjusted by placing adjustable leveling feet at the base or bottom end of the vertical uprights to compensate for uneven floors. The level of the grid structure is adjusted by continuously adjusting adjustable leveling feet at the base of one or more vertical uprights of the grid framework structure and checking the level of the grid structure at the top of the grid structure each time an adjustment is made by using an appropriate leveling measuring instrument, such as, for example, a laser level, commonly known in the art. In most cases, a special tool is required to rotate a threaded shaft so that the height of the adjustable leveling feet can be changed. However, the problem with this approach is the separation between the adjustable feet and the grid structure, the height of which can exceed 21 containers or storage bins, and this separation makes it tedious and time-consuming to incrementally adjust the level of the top level grid structure. Furthermore, the weight and variable forces that the grid framework structure is continuously subjected to during its operation may cause the first level grid structure to become uneven over time, requiring the level of the grid structure to be adjusted periodically.This requires a user to identify uneven areas of the grid structure and make adjustments at the base of the grid framework structure, which may include adjusting one or more adjustable leveling feet at the base of one or more vertical uprights, and periodically inspecting the level of the grid structure at the top. The time and effort required to periodically inspect the level of the grid structure at the top of the structure and adjust the adjustable leveling feet at the base of the grid framework structure becomes problematic because the inspection of the level of the grid is not performed in real time or simultaneously where the adjustments are being made.

[0099] To overcome this problem, an adjustable grid leveling mechanism is interposed between the top of the vertical uprights and the grid structure. This allows grid level adjustments to be made at the point where grid level measurements are being made. Thus, grid level adjustments can be made in situ or in real time as measurements are being made. An example of moving the adjustable grid leveling mechanism to the connections at the top ends of the vertical uprights is shown in FIG. 38, which represents an embodiment (sixth embodiment) in which a grid structure 740 is supported at alternative nodes or intersections where grid members intersect within the grid structure 740. In a particular embodiment of the invention shown in FIG. 38, grid members 718, 720 include track supports having a box cross-sectional shape that are connected together at the nodes or intersections 50 by suitable connecting joints 724. In a particular embodiment of the invention, the connecting joints are adjustable grid leveling mechanisms 724. Details of the adjustable grid leveling mechanisms 724 are described below with reference to FIG. 41.

[0100] The tracks 722a, 722b are attached to track supports 718, 720 and guide one or more loading devices on a grid structure 740. One or more fasteners 719 can be used to secure the tracks 722a, 722b to the track supports 718, 720. The tracks 722a, 722b are secured to the track supports 718, 720 at nodes 50 where the track supports 718, 720 intersect within the grid structure 740. In the particular embodiment shown in FIG. 39, the tracks 722a, 722b are secured to the track supports 718, 720 by threaded bolts 719 that threadingly engage adjustable grid leveling mechanisms 724. Also, as shown in FIG. 39 and clearly shown in FIG. 40, the ends 721 of the tracks are V-shaped with a substantially 45° angle that meet where the tracks intersect at nodes 50 of the grid structure to provide a stable joint. The V-shaped ends of the tracks improve the stability of the tracks at the intersections where the tracks meet at the nodes. As shown in Figure 40, the V-shaped ends of the tracks are mainly at the nodes where the grid structure is not supported by the vertical uprights.

[0101] As an alternative to the cap plate described above with reference to FIG. 8, the connecting joint or adjustable grid leveling mechanism 724 comprises a head 726 with a nodule or molded boss 728 attached to a central post or shaft 730 (see FIG. 41). The nodule or molded boss 728 is receivable in the box sections at the open ends of the track supports 718, 720 at the intersections or nodes of the grid structure (see FIG. 38). Four nodules or bosses 728 are shown extending vertically from the central post or shaft 730 and positioned to be received in the four track supports at the nodes or intersections 50. The central post 730 threadably engages an insert 732 receivable in the hollow central section of the vertical upright 716. The central post 730 can be extended or contracted relative to the insert to adjust the height of the head and thus the level of the grid structure at the nodes or intersections. FIG. 41(a) shows the head 726 of the connection joint 724 in a contracted configuration, and FIG. 41(b) shows the head 726 of the connection joint 724 in an extended configuration relative to the insert. A threaded post or shaft 730 can be extended or contracted relative to the insert to adjust the height, and therefore the level, of the track support mounted thereon. To further secure the track support to the connection joint 724, a nodule or boss 728 of the head 726 is received in a box section of the track support, each of the nodules being provided with a hole 734 for receiving a bolt that is threaded into a hole in the track support 718, 720 near its end. The connection joints 724 are used to join the track supports 718, 720 to the vertical uprights 716 at alternate intersections or nodes 50 of the grid structure 740. An L-shaped bracket 736 can be used to join the track supports 718, 720 at other nodes or intersections not supported by the vertical uprights, (see FIG. 38). The ends of the tracks 722a, 722b abut against each other in a grid structure 740 at junctures where the track supports 718, 720 are not supported by vertical uprights.As mentioned above, the ends of the tracks 722a, 722b are V-shaped to provide lateral stability to the ends of the tracks 722a, 722b within the grid structure 740 (see FIG. 40).

[0102] The inclusion of an adjustable grid leveling mechanism between the grid structure and the tops of the vertical uprights may be applied to all of the embodiments of the invention described with reference to Figures 13 to 36. An adjustable grid leveling mechanism interposed between the grid structure and the tops of the vertical uprights may be used in combination with an additional adjustable grid leveling mechanism at the foot or bottom of the vertical uprights. For example, a coarse leveling adjustment may be made at the foot of one or more vertical uprights, and then a fine grid leveling adjustment may be made at the grid structure.

[0103] In all of the embodiments of the invention described with reference to Figures 13 to 41, a section of the grid structure comprising four adjacent grid cells is supported by no more than five vertical uprights.

[0104] Further features of the invention include the following:

[0105] A. A grid framework structure configured to support one or more load handling devices, comprising: a truss assembly comprising a plurality of spaced apart parallel trusses in a horizontal plane, each of the plurality of trusses comprising upper and lower chords connected to one another by one or more diagonal braces and / or one or more straight vertical members; The plurality of trusses are connected together by a plurality of straight parallel upper cross members extending in a first direction; a plurality of straight parallel upper cross members connecting the plurality of trusses spaced apart in a second direction along the longitudinal length of each of the plurality of trusses; the first direction is substantially perpendicular to the second direction such that the upper chords of the plurality of trusses and the plurality of straight parallel upper cross members connecting the plurality of trusses are arranged in a grid-like pattern to form a grid structure comprising a plurality of grid cells; the grid structure comprising a plurality of tracks or rails for a loading device to move one or more containers on the grid structure; The truss assembly is a grid framework structure supported above ground by a plurality of vertical uprights to create a storage space for storing one or more containers in a stack so that, in use, one or more material handling devices operating on the grid structure can lift one or more containers from the stack below the grid structure and through the grid cells.

[0106] B. The grid framework structure of feature A, wherein the upper chords of adjacent trusses are connected together by a plurality of straight parallel upper cross members.

[0107] C. The grid framework structure of any one of A to B, wherein adjacent trusses are connected together with a plurality of straight parallel lower cross members.

[0108] D. The grid framework structure of Feature C, wherein the lower chords of adjacent trusses are connected together by a plurality of straight parallel lower cross members.

[0109] E. The grid framework structure of Feature D, wherein the straight parallel lower cross members connecting the plurality of trusses are spaced apart in a second direction along the longitudinal length of each of the plurality of trusses, and the lower chords of the plurality of trusses and the straight parallel lower cross members extending between the plurality of trusses are arranged in a grid-like pattern to form a grid structure including a plurality of grid cells that cooperate with a grid structure formed by the upper chords and the straight parallel upper cross members.

[0110] F. The grid framework structure of any of Features A-E, wherein the one or more diagonal braces are arranged to form a K-brace between the upper and lower chords.

[0111] G. The grid framework structure of any of Features A-F, wherein the plurality of tracks are attached to the upper chords and to a plurality of straight, parallel upper cross members extending between the upper chords.

[0112] H. The grid framework structure of Feature G, wherein the plurality of tracks are snap-fitted to the upper chords and a plurality of straight, parallel upper cross members extending between the upper chords.

[0113] I. The grid framework structure of any of Features A-F, wherein the plurality of tracks are incorporated into upper chords and a plurality of straight, parallel upper cross members extending between the upper chords.

[0114] J. The grid framework structure of any of Features A to I, wherein the truss assembly is supported by at least one of the plurality of vertical uprights at a corner of the truss assembly.

[0115] K. The grid framework structure of Feature J, wherein at least one of the plurality of vertical uprights at a corner of the truss assembly is braced by at least one brace member, such that the at least one brace member extends between at least one of the plurality of vertical uprights at the corner of the truss assembly.

[0116] L. The grid framework structure of Feature K, wherein at least one brace member is a diagonal brace member.

[0117] M. The grid framework structure of Features K or L, wherein four vertical uprights are positioned at four corners of the truss assembly to form a substantially rectangular parallelepiped structure.

[0118] N. The grid framework structure of any of Features J through M, wherein at least one of the plurality of vertical uprights at a corner of the truss assembly includes an adjustable foot for adjusting the height of the grid structure.

[0119] O. The grid framework structure of any of Features A through N, wherein at least one of the plurality of trusses is molded or extruded.

[0120] P. The grid framework structure of Feature O, wherein at least one of the plurality of trusses is fabricated from a fiber reinforced composite material.

[0121] Q. The grid framework structure of Feature O or P, wherein at least one of the plurality of trusses is constructed from a polymeric material.

[0122] R. The grid framework structure of any of Features A-Q, wherein an upper chord and / or a lower chord of at least one of the plurality of trusses is tubular or I-beam.

[0123] S. A grid framework structure comprising: i) a first modular storage unit frame arranged to define a first storage volume when assembled for storage of a plurality of stacks of containers; ii) a second modular store unit frame arranged to define a second storage volume when assembled for storage of a plurality of stacks of containers, the first modular store unit frame and the second modular store unit frame configured to be arranged together to define a storage volume comprising at least a portion of the first storage volume and the second storage volume; iii) a grid structure including a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the first direction being substantially perpendicular to the second direction to form a grid pattern including a plurality of grid cells; and a grid framework structure including: a grid structure attached to at least one of the first modular storage unit frame and the second modular storage unit frame such that at least one of the first modular storage unit frame and the second modular storage unit frame supports a plurality of grid cells such that, in use, a handling device operating on the grid structure can remove containers from the storage volume.

[0124] T. The grid framework structure of feature S, wherein the first modular storage unit frame and the second modular storage unit frame are configured to be positioned side-by-side or stacked.

[0125] U. The grid framework structure of feature T, wherein the grid structure extends across the first modular storage unit frame and the second modular storage unit frame.

[0126] V. The grid framework structure of any of Features S-U, wherein each of the first modular storage unit frame and the second modular storage unit frame comprises a container frame comprising four vertical uprights arranged in a substantially rectangular shape braced together by at least one brace member.

[0127] W. The grid framework structure of Feature V, wherein at least one brace member is a straight brace member and / or a diagonal brace member.

[0128] X. The grid framework structure of any of Features P-S, wherein the first modular storage unit frame and the second modular storage unit frame are coupled at one or more connection surfaces of the first modular storage unit frame and the second modular storage unit frame.

[0129] Y. The grid framework structure of any of Features P-T, wherein each of the first modular storage unit frame and the second modular storage unit frame are flat packed.

[0130] Z. A storage system comprising: i) a grid framework structure defined by any of features S through Y; ii) multiple stacks of containers arranged under a grid structure, each occupying a single grid space or grid cell; iii) one or more load handling devices remotely operated to move one or more containers stored on the grid framework structure, each of the one or more load handling devices comprising: i) a wheel assembly for guiding the loading device on the grid structure; ii) a container receiving space disposed above the grid structure; and and iii) a lifting device arranged to lift a single container from the stack into the container receiving space.

Claims

1. A grid framework structure configured to support one or more load handling devices 30, said grid framework structure comprising: i) a first set of grid members 18 extending in a first direction and a second set of grid members 20 extending in a second direction, said first direction being substantially perpendicular to said second direction, forming a grid structure 40 comprising a plurality of grid cells 17 lying in a horizontal plane; ii) a plurality of vertical uprights 16 for supporting said grid structure 40 above ground to create a storage space for storing one or more containers 10 in a stack such that, in use, one or more loading devices 30 operating on said grid structure 40 can lift one or more containers 10 from the stack below said grid structure 40 through the grid cells 17; 2. A grid framework structure comprising: a grid structure including a plurality of vertical uprights arranged such that a section of the grid structure comprising four adjacent grid cells is supported by five or fewer vertical uprights.

2. The grid framework structure of claim 1 , wherein the sections of the grid structure (40) comprise corner sections (102) of the grid structure (40).

3. 3. The grid framework structure of claim 1 or 2, wherein the grid structure (40) has a rectangular or square configuration with four corner sections (102), each corner section (102) supported by a single vertical upright (16).

4. The grid framework structure of claim 3 , wherein the vertical uprights (16) are braced together by at least one brace member (104, 106).

5. 5. The grid framework structure of claim 4, wherein the at least one brace member (104, 106) extends longitudinally between the tops of the vertical uprights (16) to form a substantially rectangular or square perimeter brace structure or frame (105).

6. 6. The grid framework structure of claim 4 or 5, wherein the at least one brace member (104, 106) is a diagonal brace member (106) or a straight horizontal brace member (104).

7. 3. The grid framework structure of claim 2, wherein the plurality of vertical uprights 16 comprises four vertical frame members 220, 320 arranged in a rectangular or square configuration to define one or more grid cells 17 for one or more containers 10 stacked between the four vertical frame members 220, 320.

8. The grid framework structure of claim 7 , wherein a pair of said four vertical frame members (220, 320) are braced together by at least one diagonal brace member (222).

9. 2. The grid framework structure of claim 1, wherein the first set of grid members 18 and the second set of grid members 20 intersect at nodes 50, and the plurality of vertical uprights 16 are positioned to support the grid structure 40 at alternating nodes 50 in the first direction and the second direction.

10. 10. The grid framework structure of claim 1 or 9, wherein the plurality of vertical uprights 16 are positioned to guide one or more containers 10 in a stack along a pair of diagonally opposed corners of the one or more containers 10.

11. 3. The grid framework structure of claim 1 or 2, wherein the vertical uprights are braced together by at least one brace member extending from each of the vertical uprights to form a modular frame.

12. The grid framework structure of claim 11 , wherein the grid structure (50) is supported by one or more modular frames (502).

13. The grid framework structure of claim 12, wherein the one or more modular frames 502 are arranged in a stack such that the one or more stacks of containers 10 extend through the one or more modular frames 502.

14. 14. The grid framework structure of claim 1, wherein the grid structure 40 supports a number of tracks or rails 22a, 22b for a loading device 30 to move one or more containers 10 over the grid structure 40.

15. The grid structure 40 comprises: i) an upper grid structure 440a; ii) a lower grid structure 440b, each of the upper 440a and lower 440b grid structures comprising a first set of grid members 18 extending in the first direction and a second set of grid members 20 extending in the second direction to form a plurality of grid cells 17, the upper grid structure 440a being vertically spaced from the lower grid structure 440b such that the grid cells 17 of the upper grid structure 440a are aligned with the grid cells 17 of the lower grid structure; 3. The grid framework structure of claim 1 or 2, wherein the upper grid structure 440a and the lower grid structure 440b are connected together by a plurality of diagonal 404 and straight 410 brace members to form a truss assembly.

16. 16. The grid framework structure of claim 15, wherein the plurality of diagonal 404 and straight 404 brace members extend between either opposing first or second sets of grid members in the upper grid structure 440a and the lower grid structure 440b.

17. 17. The grid framework structure of claim 16, wherein the plurality of diagonal brace members 404 are arranged to form a K or X brace between the opposing first or second sets 18, 20 of grid members in the upper and lower grid structures 440a, 440b.

18. 18. The grid framework structure of claim 15, wherein a plurality of tracks 22 are attached to the upper grid structure 440a.

19. 20. The grid framework structure of claim 18, wherein the first set of grid members comprises a first set of track supports 18, the second set of grid members comprises a second set of track supports 20, and the plurality of tracks 22 are snap-fitted to the first set of track supports 18 and the second set of track supports 20.

20. 20. The grid framework structure of any one of claims 15 to 19, wherein the grid structure (40) has a rectangular or square configuration with four corner sections (102), each corner section (102) supported by a single vertical upright (16).

21. 21. A grid framework structure according to any one of claims 1 to 20, wherein the grid structure 40 is manufactured from a fibre reinforced composite material.

22. 21. A grid framework structure according to any one of claims 1 to 20, wherein the grid structure 40 is manufactured from a polymer material.

23. 23. The grid framework structure of any one of claims 1 to 22, wherein the first set of grid members 18 and the second set of grid members 20 are tubular or I-beam.

24. 1. A storage system comprising: i) a grid framework structure as defined in any one of claims 1 to 23; ii) a plurality of stacks of containers 10 disposed beneath said grid structure 40, each stack occupying a single grid space or grid cell 17; iii) one or more load handling devices 30 that are remotely operated to move the one or more containers 10 stored on the grid framework structure, each of the one or more load handling devices 30 comprising: i) a wheel assembly for guiding the loading device 30 on the grid structure; ii) a container receiving space 41 located above said grid structure 40; iii) a lifting device arranged to lift a single container 10 from the stack into said container receiving space 41.

25. 25. The storage system of claim 24, wherein the lifting device comprises a lifting drive assembly, a grabber device 39 configured in use to releasably grasp a container 10 and lift the container from the stack into the container receiving space 41, and a drive mechanism operably arranged to move the handling device 30 on the grid structure 40.

Images