Storage system and storage container

Abstract

A separate top having a top side wall portion and a top end wall portion.SOLUTION: A storage container for storing one or more items, wherein the track system comprises a plurality of grid spaces, wherein the stacks are located below the track system, and wherein each stack occupies a single grid space. The storage container comprises a metal container body formed as a single unitary body and comprising a base having a container bottom wall and upwardly upstanding base side and end wall portions for defining a tray, and a separate top having top side and end wall portions extending upwardly from and connected to respective base side and end wall portions to form a box-like structure having an open end for receiving one or more items in the box-like structure.SELECTED DRAWING: FIG. 17 a

Description

[Technical Field]

[0001] The present invention relates to the field of storage systems comprising load handling devices operating on trucks located on a grid framework structure for handling storage containers stacked in the grid framework structure, and storage containers for use in such storage systems. [Background technology]

[0002] Some commercial and industrial activities require systems that allow for the storage and retrieval of a large number of different products. One known type of system for storing and retrieving items in multiple product lines involves placing storage containers (also known as bins or totes) on top of each other in stacks, with the stacks arranged in rows. The storage containers are removed from the stacks and accessed from above by a load handling device, eliminating the need for aisles between the rows and thereby allowing a large number of containers to be stored in a given space.

[0003] WO2015 / 185628A describes a storage and fulfilment system in which stacks of storage containers are arranged within a grid framework structure, the containers being accessed by a load handling device operating on a truck located on top of the grid framework structure.

[0004] The storage containers in such storage systems are typically made of thermoplastic materials and may be formed, for example, by injection molding or blow molding. Examples of thermoplastic materials include polypropylene, polyethylene (e.g., high density polyethylene (HDPE)), acrylonitrile butadiene styrene (ABS), and polycarbonate.

[0005] The problem with using thermoplastic storage containers in the storage systems described above is that they are highly flammable and can emit toxic fumes, and given that a storage system may contain hundreds or thousands of storage containers, the storage containers pose a significant risk in the event of a fire.

[0006] This application claims priority to GB Application No. 2106170.0, filed April 29, 2021, and GB Application No. 2201849.3, filed February 11, 2022, the contents of which are incorporated herein by reference. Summary of the Invention

[0007] The present invention alleviates the above-mentioned problems by constructing storage containers from metal. Compared to plastic materials, using metal to construct storage containers allows the storage containers to withstand much higher temperatures in the event of a fire before collapsing and emit little or no toxic fumes. In addition, more of the storage container's materials are easily recyclable, making the storage containers of the present invention more environmentally friendly. Using metal to construct storage containers also provides a sturdy structure that allows the storage containers to be stacked on top of each other in a storage and retrieval system. The present invention provides a storage container for storing one or more items in a storage and retrieval system that includes a track system and a plurality of stacks of storage containers, the track system including a first set of parallel rails or tracks and a second set of parallel rails or tracks running transversely to the first set of parallel rails or tracks in a substantially horizontal plane to form a grid pattern including a plurality of grid spaces or grid cells, the plurality of stacks being positioned below the track system, and each stack of the plurality of stacks of storage containers is a metal container body and occupies a single grid space or grid cell. The storage container comprises a metal container body formed as a single unitary piece and including a base having a container bottom wall and upwardly upstanding base side and end wall portions to define a tray, and a separate top having upper side and end wall portions extending upwardly from and connected to the respective base side and end wall portions of the base to form a box-like structure having an open end for receiving one or more items within the box-like structure.

[0008] In accordance with the present invention, a plurality of stacks of storage containers are provided, each storage container of the plurality of stacks of storage containers comprising a metal container body having a container bottom wall and upwardly upstanding, opposed side and end walls. Each stack of the plurality of stacks of metal storage containers is located below the track system and occupies a single grid space or grid cell. The metal container body can form an integral part of the storage container, in the sense that the metal container body is the storage container, or can be a separate part of the storage container, in the sense that the metal container body forms part of the storage container, for example, the metal lining.

[0009] Typically, storage containers in the art are formed from plastic materials as a single unit. Considering that thousands of storage containers are required in a typical storage and retrieval system, the storage containers present considerable bulk when transporting them, which ultimately results in significant transportation costs. Making storage containers fire-resistant and easily transportable at lower cost presents a challenge in the industry. The present invention alleviates this problem by providing a metal container body in which each metal body of a plurality of storage containers has a base formed as a single unit and a separate top connected to the base to form a box-like structure. To disassemble the metal container, the top can be separated from the base. This allows for easier packing of the storage containers, and when disassembled, the metal containers occupy a smaller volume than when they are in their assembled state. In particular, the base is stackable due to its structure of the container bottom wall and the upwardly upstanding base side and end wall portions that define a tray. Thus, when the metal container is disassembled, at least a portion of the metal container body can be stacked.

[0010] One or more robotic load handling devices operating on the track system and comprising a container receiving space are capable of lifting and lowering storage containers such that, when positioned above at least one of the plurality of stacks of storage containers occupying a grid cell, the lifting mechanism is configured to lift at least one storage container from the at least one of the plurality of stacks of storage containers into the container receiving space. Optionally, the lifting mechanism comprises a grabber device configured, in use, to releasably grasp a storage container and lift the storage container from the at least one of the plurality of stacks of metal storage containers into the container receiving space. To enable the grabber device to releasably grasp the storage container, optionally the grabber device comprises at least two gripper elements engageable with a peripheral rim surrounding an open end of the storage container. Preferably, the rim comprises one or more openings or recesses such that each of the one or more gripper elements is receivable in one or more openings or recesses in the rim of the storage container. Preferably, the peripheral rim, also referred to as the rim portion, extends around at least a portion of the periphery of the open end of the box-like structure, the rim portion including one or more openings or recesses for engagement with a grabber device of a load handling device. The rim portion may be positioned on the upper edge of the upper sidewall portion and / or upper end wall portion. In addition to allowing one or more gripper elements to be attached to the storage container, the rim portion also increases the structural rigidity of the storage container. Optionally, the rim portion is separately connected to the upper sidewall portion and / or upper end wall portion. This allows the metal container to be assembled modularly and also allows the rim portion to be formed of a different material from the remainder of the upper sidewall portion and / or upper end wall portion, optionally providing greater weight savings.

[0011] The terms "upper sidewall parts," "upper sidewall portions," and "upper sidewall" are used interchangeably throughout this patent application. Similarly, the terms "upper end wall parts," "upper end wall portions," and "upper end wall" are used interchangeably throughout this patent application. The terms "lower sidewall portion," "upright base sidewall portion," and "base sidewall portion" are used interchangeably throughout this patent application. Similarly, the terms "lower end wall portion," "upright base end wall portion," and "base end wall portion" are used interchangeably throughout this patent application.

[0012] The single piece of base provides a spill-proof tray to prevent juices from one or more items stored in the storage container, primarily food items, from contaminating one or more items stored in adjacent storage containers in the stack.

[0013] To allow multiple storage containers to be stacked on top of each other, the rim portion optionally includes a protruding lip directed inward and / or outward from the upper sidewall portion and / or upper end wall portion for supporting the container bottom wall of an upper, adjacent storage container in the stack. Each storage container in a multiple stack of storage containers is therefore stackable. The inward and / or outward protruding lip allows the container bottom wall of an upper, vertically adjacent storage container in the stack to rest on the protruding lip without the contents of the lower storage container being crushed, damaged, or soiled by the container bottom wall of the vertically adjacent storage container. Depending on whether the protruding lip projects inward or outward from the side and end walls of the storage container, the protruding lip provides a support surface for the container bottom wall of the adjacent storage container immediately above the storage container supported on the rim of the storage container.

[0014] The top of the storage container is separate from the base, such that at least one of the opposing upper side walls and / or upper end walls is separable to allow at least a portion of the metal container body to be more easily packable. Separation of the opposing upper side walls and / or upper end walls includes, but is not limited to, at least one edge or end of the opposing upper side walls and upper end walls being physically separated from each other. This includes the opposing upper side walls and / or upper end walls being physically separated from the container bottom wall. The separable nature of the opposing upper side walls and / or upper end walls also allows different portions of the storage container to be replaced if any one of the walls is damaged. This not only saves the cost of having to replace the entire storage container if any of the walls is damaged, but is also environmentally friendly, as any portion of the storage container can be replaced with a spare portion. Optionally, the upper side wall portion is separately secured to the end wall portion.

[0015] Similarly, to allow one or more of the storage containers to be stacked on top of one another without contaminating the contents of the storage container below in the stack, the metal container body of the storage container may include a plurality of stops for supporting the container bottom walls of adjacent storage containers in the stack, the stops protruding into the mouth of the storage container and located at diagonally opposite corners of the storage container, the plurality of stops being spaced above the container bottom wall to prevent the container bottom wall of an adjacent storage container above in the stack from contaminating one or more items in the storage container. For example, the storage container may include two or more stops at diagonally opposite corners of the storage container. The two or more stops protruding inward into the mouth of the storage container and are shaped to support the container bottom wall of an adjacent storage container in the stack. The two or more stops may be spaced above the container bottom wall and at diagonally opposite corners of the metal container body to prevent the adjacent storage container immediately above the storage container from crushing or contaminating the contents of the storage container. Typically, a fully loaded storage container weighs a maximum of 35 kg. 30 kg represents the weight of the stock or item, and 5 kg is the typical weight of a storage container. For a stack with 20 fully loaded storage containers, the load that the storage containers in the stack would have to withstand would be 700 kg (6,867 Newtons). To increase support for adjacent storage containers in the stack, all four corners of the storage container may be provided with stops. The stops may be integrally formed into the metal container body, for example, by recesses formed in diagonally opposite corners of the storage container.

[0016] In some implementations of storage and retrieval systems, there may be a large number of robotic load handling devices traveling on a track system with a grid framework structure comprising multiple storage containers in a stack. The significant number of storage containers used within the storage and retrieval system may hinder air circulation at or near the center of the storage and retrieval system. Additionally, it may be advantageous to cool the storage containers and their contents while they are stored within the storage and retrieval system. This may be due to the contents of the storage containers and / or to prevent the contents of the storage containers from overheating. To alleviate this problem, optionally, at least one of the upwardly upright opposing side walls and / or end walls comprises a plurality of ventilation openings. One or more ventilation openings in at least one of the upwardly upright opposing side walls and / or end walls allow cool air to circulate within the storage containers when held in a stack. For example, in a cooling zone where cool air is circulated through multiple stacks of storage containers, one or more vents in at least one of the opposing, upright side and / or end walls circulate the cool air within the storage container to keep the contents of the storage container cool. Additionally, the high thermal conductivity of metal allows heat to be easily transferred through the side and end walls of the storage container. This helps maintain the interior space within the storage container at the same temperature as the temperature outside the storage container. Therefore, compared to storage containers made of insulating plastic materials, any cooling outside the stack of storage containers is quickly conducted to the interior space of the storage container due to the relatively high thermal conductivity of the side and end walls of the storage container. However, the presence of one or more vents in the opposing, upright side and / or end walls is optional. Having solid, upright side and end walls has the advantage of preventing the spread of fire between one or more stacks of storage containers in a storage and retrieval system.

[0017] Ideally, the weight of the storage container should be a small percentage of the weight of the contents of the storage container. Typically, storage containers in the art weigh about 5 kg. This is to prevent the lifting mechanism, including the lifting motor, from being overwhelmed by the weight of the storage container and also allows contents of greater weight to be stored in the storage container. Typically, the lifting motor is sized to lift a predetermined weight, beyond which the lifting motor will struggle to lift the weight of the storage container. To keep the weight of the storage container relatively low, optionally, at least a portion of the metal container body is formed from a folded sheet metal blank so that at least a portion of the metal container body is foldable, meaning that it can be easily transported and erected for use. The foldable nature of at least a portion of the metal container body also allows multiple storage containers to be packed, transported, for example, from a supplier or another storage and retrieval system, and erected for use. Optionally, at least one of the upwardly upstanding side walls is pivotally connected to at least one of the upwardly upstanding end walls by a living hinge to enable the storage container to be erected from the sheet metal blank.

[0018] Alternatively, the side walls and end walls can be assembled together separately to form the walls of the storage container having a box-like structure with an open top or mouth. To separately assemble at least one of the side walls and end walls together, at least one of the upper side wall portions is connected to at least one of the upper end wall portions. To fixedly connect at least one of the upper side wall portions to at least one of the upper end wall portions, optionally, at least one of the upper side wall portions and / or at least one of the upper end wall portions includes at least one flange for fixedly connecting at least one of the upper side wall portions to at least one of the upper end wall portions. Each flange can be configured to either overlie or underlie an adjacent flange. The flange of at least one of the upper side wall portions can be fixedly connected to the flange of at least one of the upper end wall portions by using an adhesive or by welding or riveting. In particular, the flanges of the upper side wall portion and / or the upper end wall portion can be fastened together by a mechanical clinching process. Alternatively, the at least one upper side wall portion can be releasably connected to the at least one upper end wall portion by a snap-fit ​​joint or an interlocking joint. For example, the snap-fit ​​joint can be based on a cantilever joint. Similarly, the interlocking joint can be a toggle latch.

[0019] Optionally, each corner of the metal container body comprises multiple overlapping layers. The multiple overlapping layers reinforce the corners of the metal container body to withstand loads from one or more storage containers placed above, particularly when the storage container comprising the metal container body is placed in a stack of storage containers. This provides rigidity from the overlapping layers through the corners of the metal storage container. There may be two, three, or four overlapping layers at each corner.

[0020] Optionally, the storage container further comprises guides at each corner of the storage container for aligning grabber devices of the load handling device. The guides allow for easier alignment of the grabber devices with openings or recesses in the rim portion of the metal container. The guides may be formed by elongated vertical recesses in the flanges of the upper sidewall portion and / or end wall portion. To grip the storage container, the grabber devices use guide pins near or at each corner of the grabber devices that fit into corresponding openings or recesses formed in the four corners of the storage container.

[0021] Optionally, at least a portion of the metal container body is formed from a deep drawn sheet metal blank, where the sheet metal blank is drawn into a forming die by the mechanical action of a punch.

[0022] Alternatively, only a portion of the metal container body is formed from a deep-drawn sheet metal blank. This allows the remaining portion of the metal container body to be foldable as discussed above, allowing for easy transportation. At least one of the upwardly upright opposing side walls comprises an upper side wall portion and a lower side wall portion, and / or at least one of the upwardly upright opposing end walls comprises an upper end wall portion and a lower end wall portion. Preferably, the deep-drawn sheet metal blank forms a shallow portion of the metal container body, such that the opposing side walls and end walls upright above the shallow portion of the metal container body form the opposing lower side wall portion and lower end wall portion of the metal container body. Optionally, at least one of the upper side wall portions is pivotally attached to a respective lower side wall portion of the metal container body, and / or at least one of the upper end wall portions is pivotally attached to a respective lower end wall portion of the metal container body. The opposing side walls and end walls of the deep-drawn metal blank form the lower side wall portion and the lower end wall portion, respectively, of the metal container body. The heights of the lower side wall portion and the lower end wall portion, together with the heights of the upper side wall portion and the upper end wall portion, represent the total height of the opposing side walls and end walls of the metal container body. Thus, the side walls of the metal container may be a combination of the lower side wall portion and the upper side wall portion. Similarly, the end walls of the metal container body may be a combination of the lower end wall portion and the upper end wall portion.

[0023] Optionally, at least one of the upper side wall portions is removably attached to a respective lower side wall portion of the metal container body, and / or at least one of the upper end wall portions is removably attached to a respective lower end wall portion of the metal container body. For example, the walls of the deep drawn sheet metal blank can be used to support the upwardly upstanding opposing side and end walls of the metal container body by receiving the upwardly upstanding opposing side and end walls within the deep drawn sheet metal blank.

[0024] To prevent any one of the upwardly upright opposing side walls and / or upwardly upright opposing end walls from collapsing under the weight of one or more adjacent storage containers in the stack, the metal container body optionally includes one or more wall reinforcements configured to support at least one of the upwardly upright opposing side walls and / or at least one upwardly upright opposing end walls of the metal container body. For example, the one or more side wall reinforcements and / or end wall reinforcements can also function as inserts to reinforce any one of the upwardly upright opposing side walls and / or upright opposing end walls, thereby improving the structural integrity of the storage container to resist the weight of the stack of adjacent storage containers above it. Preferably, the one or more side wall reinforcements and / or end wall reinforcements are cast, e.g., die-cast, to provide the necessary structural integrity to the upright opposing side walls and / or upright opposing end walls of the storage container.

[0025] Alternatively, any one of the container bottom wall, the upwardly upstanding opposing side walls, and / or the upwardly upstanding opposing end walls, and / or the top wall portion may be cast. For example, the container bottom wall, the upwardly upstanding opposing side walls and / or end walls, and / or the top side wall and / or top end wall may be cast into panels that are assembled together to form the metal container body.

[0026] Alternatively, any one of the container bottom wall and / or the opposing upwardly upright side wall and / or the opposing upwardly upright end wall comprises at least a hollow portion and a filler material disposed in the hollow portion. This has the advantage of using a secondary material to improve the wall properties of the metal container body, such as acoustic properties and / or fire resistance properties. Optionally, the filler material is a thermal insulating material and / or a fire resistance material.

[0027] When one or more items stored in a storage container are food products or food items, it is essential that the food items be protected from contamination from the metal storage container. To prevent contamination of the food items, the metal container body has an inner and outer surface, preferably a polymer coating on the inner surface. The polymer coating protects the food items stored in the storage container from any potential corrosion of the metal container body. The polymer coating or lining not only minimizes any interaction between the metal container body and the food items stored therein, but also meets global food storage regulations. The polymer coating also provides an airtight coating on the inner surface of the storage container, preventing any leakage from the storage container as a result of spills. Examples of polymer coatings include, but are not limited to, resin-based coatings, acrylic-based coatings, and / or vinyl-based coatings, or combinations thereof.

[0028] To reinforce any one of the container bottom wall and / or the opposing side wall and / or the opposing end wall of the metal container body, preferably, at least a portion of the container bottom wall and / or the opposing side wall and / or the opposing end wall is reinforced by one or more ribs. Each of the one or more ribs may protrude either outward and / or inward from the surface of the wall of the metal container body to reinforce the wall of the metal container body. One or more ribs may be integrated into the container bottom wall and / or the opposing side wall and / or the end wall of the metal container body so that the container bottom wall and / or the opposing side wall and / or the end wall of the metal container body are corrugated. Alternatively, the upper side wall portion and / or the upper end wall portion may include ribs or beaks to minimize movement of the upper side wall portion and / or the upper end wall portion. Preferably, the base includes one or more patterns embossed in the container bottom wall to increase the rigidity of the base.

[0029] The present invention may further provide a foldable stackable container configured to be stacked in a storage and retrieval system, the storage and retrieval system including a track system having a first set of parallel rails or tracks and a second set of parallel rails or tracks running transversely to the first set of parallel rails or tracks in a substantially horizontal plane to form a grid pattern having a plurality of grid spaces or grid cells, the foldable stackable container including a metal container body having a container bottom wall and upwardly upstanding opposing side and end walls, and a rim having a protruding lip oriented inwardly and / or outwardly at a mouth of the storage container so that one or more of the foldable stackable containers can be stacked on top of each other, at least a portion of the metal container body being formed from a unitary blank of bendable sheet metal. For purposes of the present invention, the bendable sheet metal blank may have a thickness in the range of 0.5 mm to 2 mm, preferably in the range of 0.5 mm to 1 mm, e.g., 0.55 mm, 0.6 mm, 0.7 mm, 0.8 mm, or 0.9 mm. Forming at least a portion of the metal container body from a unitary blank of bendable sheet metal allows the metal container body of the storage container to be easily transportable because the storage container does not appear as a bulky item for transportation, as compared to existing molded plastic storage containers in the art. This allows a greater number of metal container bodies to be tightly packed and transported to a fulfillment center housing the storage and retrieval system of the present invention, where the containers can be erected for use in the storage and retrieval system.

[0030] To provide a foldable stackable container, the present invention may further provide a foldable stackable container constructed to be stacked in a storage and retrieval system, the storage and retrieval system including a track system including a first set of parallel rails or tracks and a second set of parallel rails or tracks running transversely to the first set of parallel rails or tracks in a substantially horizontal plane to form a grid pattern including a plurality of grid spaces or grid cells. The foldable stackable container includes a metal container body including a container bottom wall and upwardly upright opposing side and end walls, and a rim including a protruding lip oriented inward and / or outward at the mouth of the storage container so that one or more of the foldable stackable containers can be stacked on top of each other, at least a portion of the metal container body being cast. Casting allows the walls (container bottom wall, opposing side walls, and / or end walls) to be rigid, providing a sturdy metal container body for withstanding the weight of vertically adjacent storage containers in a stack. Optionally, the metal container body may be die-cast or investment-cast. The metal container body may be cast from aluminum or steel.

[0031] Preferably, the storage container may include a liner formed from a food-grade material. The metal container body of the storage container is non-flammable, thus allowing any type of food-grade material to be used for the liner of the storage container. The liner of the storage container is therefore not limited to being non-flammable. Optionally, the liner comprises a food-grade plastic material and / or a cellulose-based material. Optionally, the cellulose is coated or impregnated with a wax material to make the cellulose material resistant to moisture and / or oil. Optionally, the cellulose material is paper or cardboard. One way to provide a paper or cardboard liner is to form the liner from a folded paper or cardboard blank. Because the liner comprises paper or cardboard, optionally, the liner is disposable. The liner may be a shallow base or tray that provides coverage for at least a portion of the interior surface of the box-like structure of the storage container. Alternatively, the liner may extend throughout the entire interior surface of the box-like structure. Preferably, the liner is a leak-proof container to prevent juices from the food items from leaking out of the storage container and contaminating food items in storage containers below in the stack. Optionally, the leak-proof container is a one-piece thermoformed container, for example, by a blow molding or deep-draw molding process.

[0032] The present invention further provides a kit for assembling a storage container, the kit comprising: i) a base formed as a single, unitary piece and having a container bottom wall and upwardly upstanding base side and end wall portions for defining a tray; ii) a separate upper portion having an upper sidewall portion and an upper end wall portion; Equipped with.

[0033] Because the storage container comprises a separate top and base, it can advantageously be supplied as a kit of parts and assembled together, for example, by utilizing toggle latches, snap-fit ​​joints, etc., and / or by spot welding the top to the base. The storage container of the kit can include any of the features described above. The kit can further include two or more rim portions separately connectable to the top sidewall portion and / or end wall portion.

[0034] Further 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 explanation of the drawings]

[0035] [Figure 1] 1 is an illustration of an automated storage and retrieval system in accordance with an exemplary embodiment of the present invention. [Figure 2] 2 is a schematic diagram of a top view showing a stack of containers arranged within the framework structure of FIG. 1. [Figure 3] 1 is a schematic diagram of a system of known cargo handling devices operating on a grid framework structure; [Figure 4] 1 is a schematic perspective view of a load handling device showing a container receiving space within the body of the load handling device; FIG. [Figure 5(a)] 5 is a schematic perspective cutaway view of the load handling device of FIG. 4, showing a container accommodating the container receiving space of the load handling device; [Figure 5(b)] 5 is a schematic perspective cutaway view of the load handling device of FIG. 4, showing the container receiving space of the load handling device; [Figure 6] FIG. 1 is a schematic perspective view of a grabber device positioned above a storage container. [Figure 7(a)] FIG. 1 is a schematic perspective view of a grabber device mounted on a storage container. [Figure 7(b)] FIG. 1 is a schematic perspective view of a grabber device engaging with a storage container. [Figure 8] 1 is a schematic perspective view of a storage container formed by deep drawing according to a first embodiment of the present invention; [Figure 9] 1 is a schematic perspective view of a storage container formed by deep drawing according to a second embodiment of the present invention; [Figure 10(a)] 1 is a schematic perspective view of a storage container formed by deep drawing, showing an exploded view of assembled components of the storage container. FIG. [Figure 10(b)] 10 is a schematic perspective view of a storage container formed by deep drawing, showing an assembled storage container according to a third embodiment of the present invention. FIG. [Figure 11(a)] 1 is a schematic perspective view of a storage container partially formed by deep drawing, showing an exploded view of assembled components of the storage container. FIG. [Figure 11(b)] 10 is a schematic perspective view of a storage container partially formed by deep drawing, showing an assembled storage container according to a fourth embodiment of the present invention. FIG. [Figure 12] 10 is a schematic diagram of a storage container partially formed by deep drawing according to a fifth embodiment of the present invention. FIG. [Figure 13(a)] 1 is a schematic perspective view of a storage container partially formed by deep drawing, showing the storage container in a pre-assembled view. FIG. [Figure 13(b)] 10 is a schematic perspective view of a storage container partially formed by deep drawing, showing an assembled storage container according to a sixth embodiment of the present invention. FIG. [Figure 14(a)] 1 is a schematic perspective view of a storage container partially formed by deep drawing, showing the storage container in a pre-assembled view. FIG. [Figure 14(b)] 10 is a schematic perspective view of a storage container partially formed by deep drawing, showing an assembled storage container according to a seventh embodiment of the present invention. FIG. [Figure 14(c)] FIG. 1 is a schematic perspective view of an assembled storage container showing the connection of the top wall portions by a releasable toggle latch. [Figure 14(d)]FIG. 14(c) is a perspective view of a releasable toggle latch for connecting together the top wall portions of the metal container body shown in FIG. 14(c). [Figure 14(e)] 14(b) and 14(d) are perspective views of separate portions of the metal storage containers shown in FIG. 14(b) and FIG. 14(d) in a stack. [Figure 15(a)] 1 is a schematic perspective view of a storage container partially formed by deep drawing, showing the storage container in a pre-assembled view. FIG. [Figure 15(b)] 10 is a schematic perspective view of a storage container partially formed by deep drawing, showing an assembled storage container according to an eighth embodiment of the present invention. FIG. [Figure 15(c)] FIG. 13 is a schematic perspective view of an upper side wall of a storage container according to an eighth embodiment of the present invention. [Figure 15(d)] FIG. 13 is a schematic perspective view of an upper end wall of a storage container according to an eighth embodiment of the present invention. [Figure 15(e)] FIG. 13 is a schematic perspective view of an upper corner of a storage container according to an eighth embodiment of the present invention. [Figure 16] FIG. 13 is a schematic perspective view of a storage container partially formed by deep drawing, illustrating a ninth embodiment of the present invention. [Figure 17(a)] 10 is a schematic perspective view of a storage container partially formed by deep drawing, showing an assembled view of a storage container according to a tenth embodiment of the present invention. FIG. [Figure 17(b)] 10 is a schematic perspective view of a storage container partially formed by deep drawing, showing an unassembled view of a storage container according to a tenth embodiment of the present invention. FIG. [Figure 17(c)] 10 is a schematic perspective view of a storage container partially formed by deep drawing, showing a rim portion of a storage container according to a tenth embodiment of the present invention. FIG. [Figure 17(d)] 10 is a schematic perspective view of a storage container partially formed by deep drawing, showing a schematic perspective view of an upper corner of a storage container according to a tenth embodiment of the present invention. FIG. [Figure 17(e)]10 is a schematic perspective view of a storage container partially formed by deep drawing, showing a schematic perspective view of the interface between the top and base of a storage container according to a tenth embodiment of the present invention. FIG. [Figure 18] 18 is a schematic perspective view of a storage container similar to FIG. 17 and partially formed by deep drawing, showing an assembled view of a storage container according to an eleventh embodiment of the present invention. [Figure 19(a)] 1 is a schematic perspective view of a storage container partially formed by deep drawing, showing the storage container in a pre-assembled view. FIG. [Figure 19(b)] 12 is a schematic perspective view of a storage container partially formed by deep drawing, showing an assembled storage container according to a twelfth embodiment of the present invention. FIG. [Figure 20(a)] 1 is a schematic perspective view of a storage container partially formed by deep drawing, showing the storage container in a pre-assembled view. FIG. [Figure 20(b)] 13 is a schematic perspective view of a storage container partially formed by deep drawing, showing an assembled storage container according to a thirteenth embodiment of the present invention. FIG. [Figure 21] FIG. 21 is a schematic diagram of a stack of storage containers of FIG. 19 or FIG. 20 before assembly. [Figure 22(a)] 1 is a schematic perspective view of a bendable sheet metal blank; FIG. [Figure 22(b)] FIG. 22 is a schematic perspective view of a metal container body erected from a blank according to a fourteenth embodiment of the present invention. [Figure 23(a)] 1 is a schematic perspective view of a single blank of bendable sheet metal; FIG. [Figure 23(b)] FIG. 20 is a schematic perspective view of a metal container body erected from a single blank according to a fifteenth embodiment of the present invention. [Figure 24] FIG. 22 is a schematic diagram of a molded storage container according to a sixteenth embodiment of the present invention. [Figure 25] 17 is a schematic perspective view of a storage container with hollow walls according to a seventeenth embodiment of the present invention. FIG. [Figure 26]1 is a schematic diagram of a storage container comprising a fire-resistant body forming a non-combustible enclosure and a partial liner. FIG. [Figure 27] FIG. 27 is a schematic view of a partial liner of the refractory body shown in FIG. 26. [Figure 28] 1 is a schematic diagram of a storage container with a fire-resistant body forming a non-combustible enclosure and a full-height liner. FIG. [Figure 29] FIG. 29 is a schematic diagram of a full-height liner of the refractory body shown in FIG. 28. DETAILED DESCRIPTION OF THE INVENTION

[0036] As shown in FIGS. 1 and 2 , storage containers 10, also known as bins or totes, are stacked on top of one another to form stacks 12. The stacks 12 are arranged in a grid framework structure 14 in a warehouse or manufacturing environment. The grid framework is made up of multiple storage rows or grid columns. Each grid in the grid framework structure has at least one grid column for storing stacks of containers. FIG. 1 is a schematic perspective view of the grid framework structure 14, and FIG. 2 is a top view showing a single stack 12 of containers 10 arranged within the framework structure 14. Each container or receptacle 10 typically holds multiple product items (not shown), which may be the same or different product types depending on the application. Each container 10 may be used to store grocery items (i.e., food items), for example. Furthermore, the receptacle 10 may be physically subdivided to accommodate multiple different inventory items.

[0037] In the following description, vessel 10 will be used to refer to a storage container intended to store inventory items, while shipping container DT will be used to refer to a container that has been filled or is intended to be filled to fulfill a customer order placed by a customer. It should be recognized that this terminology is used for ease of reference and description within this document. However, it should be noted that vessel 10 and container DT may be the same shape and configuration. Furthermore, shipping container DT may be stored in vessel 10 within a storage system or any portion thereof.

[0038] The grid framework structure 14 comprises a plurality of upright members or columns 16 that support horizontal members 18, 20. A first set of parallel horizontal grid members 18 is arranged perpendicular to a second set of parallel horizontal grid members 20 to form a multiple horizontal grid structure supported by the upright members 16. The members 16, 18, 20 are typically fabricated from metal and are typically welded or bolted together, or a combination of both. The containers 10 are stacked between the members 16, 18, 20 of the grid framework structure 14 so that the framework structure 14 prevents horizontal movement of the stack 12 of containers 10 and guides vertical movement of the containers 10.

[0039] The top level of the grid framework structure 14 includes rails 22 arranged in a grid pattern across the top of the stacks 12. Referring additionally 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., the 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., the Y direction) perpendicular to the first direction. In this manner, the rails 22 enable movement of the robotic load handling device 30 laterally in two dimensions in the horizontal XY plane, thereby allowing the load handling device 30 to be moved to a position above any stack 12.

[0040] Each load handling device 30 comprises a vehicle 32 arranged to move in the X and Y directions above the stack 12 on the tracks or rails 22 of the grid frame structure 14 (see FIG. 4). FIGS. 4 and 5 show a load handling device 30 according to an embodiment of the present invention and described in PCT Patent Publication No. WO2015 / 019055 (Ocado Innovation Limited) and International Patent Application No. WO2015 / 140216 (Ocado Innovation Limited), the contents of which are incorporated herein by reference. The load handling device 30 comprises a vehicle body 32 fitted with a lifting mechanism 33 (see FIG. 4) comprising a winch or crane mechanism 35 for lifting the storage containers or receptacles 10, also known as totes, from above. The crane mechanism 35 comprises a winch cable 38 wound on a spool or reel and a grabber device 39. Typically, the lifting device extends vertically and includes a set of lifting tethers 38 near or connected to the four corners of the grabber device 39 (one tether near each of the four corners of the grabber device) for releasable connection to the storage container 10. The grabber device 39 is configured to grasp 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. Typically, the grabber device 39 is configured as a lifting frame. Further details of the grabber device are discussed below.

[0041] The vehicle body 32 comprises an upper and lower portion (see FIGS. 5(a) and 5(b)). The lower portion is fitted with two sets of wheels 34, 36, which run on rails at the top of the framework structure of the storage system. The upper portion of the vehicle body 32 may house most of the bulky components of the load handling device. Typically, the upper portion of the vehicle body houses a drive mechanism for driving both the wheels and the lifting mechanism, along with an on-board rechargeable power source for powering the drive mechanism and the lifting mechanism.

[0042] The bottom of the vehicle body 32 is provided with wheel assemblies that are driven to allow the vehicle to move in the x and y directions along the rails, respectively. A first set of wheels 34, consisting of a pair of wheels 34 at the front of the vehicle 32 and a pair of wheels 34 at the rear of the vehicle 32, is positioned to engage two adjacent rails of the first set 22a of rails 22. Similarly, a second set of wheels 36, consisting of a pair of wheels 36 on each side of the vehicle 32, is positioned to engage two adjacent rails of the second set 22b of rails 22. One or both sets of wheels can be moved vertically to lift each set of wheels off its respective rail, thereby allowing the vehicle to move in a desired direction. When the first set of wheels 34 is engaged with the first set of tracks or rails 22a and the second set of wheels 36 is lifted off the tracks or rails 22, the wheels 34 can be driven by a drive mechanism (not shown) housed within the vehicle 32 to move the load handling device 30 in the x direction. To move the load handling device 30 in the Y direction, the first set of wheels 34 is lifted off the tracks or rails 22b and the second set of wheels 36 is lowered into engagement with the second set of tracks or rails 22b. A drive mechanism can then be used to drive the second set of wheels 36 to achieve movement in the Y direction. One or both sets of wheels can be moved vertically to lift each set of wheels off its respective rail, thereby allowing the vehicle to move in a desired direction on the track system.

[0043] The wheels are positioned at the bottom around the periphery of a cavity or recess known as a container-receiving recess 40. The recess 40 is sized to accommodate the storage container or receptacle 10 when it is lifted by a crane mechanism, as shown in FIGS. 5(a) and 5(b). When in the recess, the container is lifted off the rails below, allowing the load handling device to move laterally to different locations. Upon reaching a target location, such as another stack, an access point in the storage system, or a conveyor belt, the receptacle or storage container can be lowered from the container-receiving space and released from the grabber device 39. In this manner, as shown in FIG. 3, one or more robotic load handling devices 30 can move around the top of the stacks 12 on the frame structure 14 under the control of a centralized control utility (not shown). Each robotic load handling device 30 is provided with a lifting mechanism 38 for lifting one or more receptacles 10 from the stack 12 to access needed items stored therein.

[0044] The body of the vehicle 32 may be provided with a container-receiving space in the form of a cavity 40 for accommodating the container 10 (see FIG. 5 ). The cavity 40 is sized to hold the receptacle or storage container 10. A lifting mechanism comprising a set of vertically extending lifting tethers 38 is connected to the four corners of a lifting frame (not shown), also known as grabber devices, for releasable connection to the storage container (one tether near each of the four corners of the grabber device). The grabber devices are configured to releasably grasp the top of the storage container to lift the storage container from a stack of containers in a storage system of the type shown in FIGS. 1 and 3 . The lifting mechanism lifts the container 10 from the stack 12 into the cavity 40 in the body of the vehicle 32. While the container-receiving space 40 for accommodating the container 10 when it is lifted by the winch means is located within the vehicle body 32 as shown in FIG. 4 , the present invention is not limited to the container-receiving space 40 being located within the vehicle body 32. The present invention is also applicable when the container receiving space is located below the cantilever, such as when the vehicle body of the load handling device has a cantilever structure as described in WO 2019 / 238702 (Autostore Technology AS). For the purposes of the present invention, the term "vehicle body" is interpreted as optionally covering the cantilever so that the grabber device is located below the cantilever. However, for ease of explanation of the present invention, the container receiving space for receiving the container is located within a cavity or recess within the vehicle body. The container receiving space allows multiple products to be accessed from multiple locations in the grids and stacks at any one time.

[0045] The robotic load handling device 30 retrieves the container 10 containing inventory items (not shown) therein and transports the container 10 to a picking station (not shown) where the required inventory items 28 are removed from the container 10 and placed into the container 10 with a shipping container DT. It is important to note that the shipping container DT may fit within the container 10. The container 10 may contain inventory items or may comprise a shipping container DT. Additionally, the shipping container DT may comprise at least one bag and the inventory items are picked directly into the bag at the picking station (not shown).

[0046] Empty containers 10, or containers with shipping containers DT, or containers with shipping containers DT and bags may all be stored in the stack 12. It should be appreciated that all containers 10 have substantially the same shape and configuration.

[0047] Figure 3 illustrates a typical storage and retrieval system as described above, having a plurality of load handling devices 30 operating on a grid above stacks 12. Figures 1 and 3 illustrate receptacles 10 in stacks 12 within the storage system. It should be recognized that there may be many storage containers or receptacles 10 in any given storage system, many different items may be stored in receptacles 10 in stacks 12, and each receptacle 10 may contain a different category of inventory item within a single stack 12.

[0048] In one storage and retrieval system described above, and further in UK Patent Application No. GB1410441.8 (Ocado Innovation Limited), which is incorporated herein by reference, the storage and retrieval system comprises a series of bins 10 which may further comprise delivery containers DT having customer orders contained therein, or which may further comprise bins 10 having inventory items awaiting picking contained therein. These different bins 10 and combinations thereof may be housed in the storage system and accessed by the robotic load handling device 30 as described above.

[0049] FIG. 6 shows a grabber device positioned above one form of receptacle 10 for use within the storage and retrieval system of FIGS. 1-3. The storage container or receptacle 10 comprises a substantially box-shaped structure having an open top 43, a container bottom wall 44, and opposing side walls 46 (a and b), and end walls 48 (a and b). In the particular example shown in FIG. 6, the receptacle 10 has a container bottom wall 44 that is substantially rectangular in shape, such that the length of the opposing side walls 46 (a and b) is greater than the length of the opposing end walls 48 (a and b). The opposing side walls 46 (a and b) and end walls 48 (a and b) of the receptacle comprise one or more ribs for stiffening the side and end walls of the storage container. Multiple receptacles 10 may be stacked into a freestanding stack 12, and multiple stacks 12 may be arranged within a grid framework structure 14 as described above. It should be appreciated that in a storage facility of the type described with reference to FIGS. 1-3, there may be a large number of receptacles 10, potentially hundreds of thousands of receptacles 10. Typically, each container 10 must be able to withstand the load of multiple containers 10 in the stack. The load of a container stack is supported by the maximum load of 20 fully loaded containers. A fully loaded container weighs approximately 35 kg, of which 5 kg represents the weight of the container alone. For example, a stack of 20 containers 10 would represent a load of 700 kg or 6,867 N. One or more ribs on the opposing side and end walls strengthen the side and end walls to prevent them from buckling under such loads in a stack.

[0050] To allow air to flow through the containers 10 when held in a stack, the side walls 46(a and b) and / or end walls 48(a and b) of the containers 10 include one or more slots, openings, or vents 50. The slots or openings 50 in the side walls 46(a and b) and / or end walls 48(a and b) allow air circulating in and through the storage and retrieval system to flow through the containers 10. This is particularly important when the containers 10 are located in a cooling zone of a storage and retrieval system where cool air from a refrigeration or air conditioning unit circulates through at least a portion of a grid framework structure to keep items, such as grocery items, at a cool temperature. Cooling systems such as those described in International Patent Publication No. WO 2016 / 193419 (Ocado Innovation Limited) require air to flow through the storage system and past the containers 10 and stacks 12 of containers 10. The system described in this International Patent Application, which is incorporated herein by reference, discloses a storage system that includes one or more heaters and / or one or more chillers for generating temperature-controlled gas, one or more fans for circulating the temperature-controlled gas through the storage system, and a plenum for receiving the temperature-controlled gas. For example, when portions of a storage and retrieval system need to be cooled to lower temperatures to allow for the storage of items that require cooling, such as fruits and vegetables, it is more important that airflow through the system cools the stored items. While embodiments herein are described with respect to cooling the storage system, it should be appreciated that items stored in the storage system can be heated in a similar manner using the same methods described. Furthermore, while the above description refers to airflow, it should be appreciated that any suitable gas can be circulated to heat or cool the system as needed.

[0051] In addition to allowing air to circulate within the container, the slots 50 in the container 10 allow the same amount of storage volume to be utilized while maintaining the structural integrity of the container 10, yet reducing the weight of the container 10. Advantageously, providing apertures 50 in the container DT or receptacle 10 also reduces the cost of each container DT or receptacle. In a storage and retrieval system 1 comprising hundreds of thousands of containers and receptacles, this can represent a significant savings. In the illustration of the container 10 shown in FIG. 6, two sides of the container or receptacle include openings or holes 50. One or more handles 52 are integrally formed in the end walls 48(a and b) of the container 10 to allow the storage container to be manually picked up by an operator. The openings or vents 50 in the side walls 46(a and b) and / or end walls 48(a and b) are located at a predetermined height above the bottom wall 44 of the storage container 10 to provide a leak-proof base, thereby preventing accidental leakage of fluid from the contents of a storage container from contaminating the contents of adjacent storage containers in the stack.

[0052] Also shown in Figure 6 is a grabber device 39 that forms part of the lifting mechanism 33 of the robotic load handling device and is positioned above the container 10. The lifting mechanism 33 used to lift the container into the container receiving space can take any suitable form and comprises a winch or crane mechanism (see Figure 4). The crane mechanism comprises a winch cable 38 wound on a spool or reel and a grabber device 39. The grabber device 39 is configured to grip the top of the container 10 to lift it from a stack of containers in a storage system of the type shown in Figures 1 and 2. Typically, the grabber device 39 is configured as a frame 54, with four lifting tethers 38 secured to each corner of the grabber device 39 (see Figure 5b). For maximum stability and load capacity, typically four lifting tethers 38 are used to hoist the grabber device 39, one tether disposed near or at each corner of the grabber device 39, although a different arrangement, e.g., an arrangement with fewer tethers, can be used if desired. One end, e.g., the first end, of each of the tethers is wound onto a spool in the load handling device, and the other end, e.g., the second end, is secured to the grabber device 39 by suitable brackets (not shown), typically at each corner of the grabber device. The number of tethers attached to the grabber device depends on the ability to maintain the grabber device level during operation when picking up a container 10 and the ability of the tethers to withstand, without stretching or stretching, the tension applied to the tethers when lifting containers that can weigh up to 40 kg, i.e., to be inextensible under a given applied tensile stress. In order to have the necessary physical properties (Young's modulus), the tether is generally in the form of a tape, although other tethers having the necessary physical properties to reel in the container are acceptable to reel in the container from the stack.

[0053] In the particular embodiment shown in FIG. 6 , the grabber device frame 54 has four corner sections 56, a top side, and a bottom side. To grip the container 10, the grabber device 39 includes four locating or guide pins 58 near or at each corner of the grabber device 39 that mate with corresponding notches or holes 60 formed in the four corners of the container 10, and four gripper elements 62 located on the bottom side of the grabber device 39 for engaging a rim 64 of the container 10 (see FIG. 7 a). The locating pins 58 help properly align the gripper elements 62 with the corresponding holes 60 in the container's rim 64. In the particular embodiment shown in FIG. 7 a, each of the gripper elements 62 includes a pair of foldable wings 66 that are receivable in the corresponding holes 60 in the container's rim 64, and an open, expanded configuration that is larger in size than the holes 60 in the container's rim 64 in at least one dimension so as to lock onto the container 10 (see FIG. 7 b). The wings are driven into the open configuration by a drive gear (not shown). More specifically, the head of at least one of the wings includes a plurality of teeth that mesh with the drive gear, so that when the gripper element 62 is actuated, rotation of the drive gear rotates the pair of wings from a folded configuration (FIG. 7a) to an open, expanded configuration (FIG. 7b).

[0054] When in the folded or closed configuration, the gripper elements 62 are sized to be receivable within corresponding holes 60 in the rim 64 of the container 10, as shown in Figure 7a. The foot of each of the pair of wings includes a stop 68 (see Figure 6), e.g., a boss, so that when received within a corresponding hole 60 in the rim 64 of the container 10, the stop 68 engages the underside of the rim 64 when in the wide open configuration to lock onto the container when the grabber device 39 is rolled upwardly toward the container receiving space of the load handling device. Figure 7b shows the arrangement of the gripper elements in the wide open configuration for lifting a container 10 into the container receiving space of a robotic load handling device.

[0055] Gripper elements 62 are received in holes 60 in rim 64 in container 10 when grabber device 39 is at a predetermined height above the rim of the container as measured by one or more depth sensors (not shown) mounted on the underside of the grabber device. At this depth, gripper elements 62 are actuated to grasp container 10 in response to signals from one or more of the depth sensors (not shown) mounted on the underside of grabber device 39.

[0056] Typically, the container 10 is largely made of thermoplastic material and is either injection molded or blow molded. Known thermoplastic materials commonly used to form storage containers include polyolefins, such as polypropylene or polyethylene (e.g., high-density polyethylene (HDPE)), acrylonitrile butadiene styrene (ABS), and polycarbonate (including their copolymers). However, a problem with such plastic materials is that they are flammable and emit toxic fumes. If a fire were to break out within the storage and retrieval system, the flammability and exothermic nature of the container 10 material would result in the fire spreading throughout the storage and retrieval system, posing a risk to life. Not only is the container 10 flammable, but the combustion fumes emitted from burning thermoplastic materials are highly toxic and include benzene, a known carcinogen. Inhalation of fine particles resulting from burning debris can cause respiratory irritation. As a result, extreme fire prevention methods and systems, such as sprinklers and smoke / heat detection units, are incorporated into the storage and retrieval system to prevent the rapid spread of fire. Although efforts have been made to prevent the rapid spread of fire, with the container 10 playing a major role in the spread of fire, the problem of fire spreading throughout the storage and retrieval system still exists.

[0057] The present invention alleviates the above-mentioned problems by providing a storage container comprising a metal container body having a container bottom wall, opposing side walls, and opposing end walls. In the examples of different types of storage containers discussed below with reference to Figures 8-25, the entire storage container is formed from a metal container body, in the sense that the metal container body is the storage container. However, storage containers of the present invention are not limited to being formed entirely from a metal container body, and at least a portion of the storage container can comprise other materials, such as plastic materials. For example, the metal container body can form the metal lining of the storage container. Storage containers comprising a metal container body are also applicable to shipping containers, in the sense that shipping containers DT can also comprise a metal container body of the present invention, having a container bottom wall, opposing side walls, and opposing end walls.

[0058] The storage containers described below with reference to Figures 8-25 relate to storage containers formed from metal container bodies. For ease of description, the metal container bodies in the following examples may be referred to as storage containers. The metal container bodies of the present invention may have a shape similar to currently existing storage containers for storing items in a grid framework structure, for example, having a substantially rectangular container bottom wall and opposing side and end walls. The metal storage containers may be used among conventional plastic storage containers in the storage and retrieval system described above with reference to Figure 3. The flame-resistant behavior of the metal storage containers may be used to form a flame-resistant barrier in the grid framework structure. For example, multiple stacks of metal storage containers may be arranged to form one or more flame-resistant barriers surrounding the multiple stacks of plastic storage containers. The one or more flame-resistant barriers comprising the metal storage container may be used to contain any flame within the grid framework structure.

[0059] There are numerous methods for fabricating storage containers comprising a metal container body according to the present invention. For use in automated storage and retrieval systems, an important feature of storage containers is their light weight, weighing less than 8 kg, preferably less than 6 kg, and more preferably less than 5 kg. Storage containers comprising a metal container body should also have sufficient structural rigidity to withstand the loads imposed on them when arranged in a stack. A grid framework structure can hold a stack of storage containers as high as 20 storage containers. Considering that each storage container can weigh up to 35 kg, this amounts to a total weight of 700 kg. Below are different examples according to the present invention of different storage containers comprising a metal body according to the present invention. When a storage container comprising a metal container body is used to store food items, it is important that the storage container be leakproof to prevent leakage of a food item from leaking out of the storage container and contaminating other food items stored in adjacent storage containers in the stack. Since fluids tend to pool at the base of the storage container, the base of the metal container body is made leakproof, and any vent holes in the side and / or end walls of the metal container body are located at a predetermined height above the container bottom wall to prevent leakage of fluids through the vent holes.

[0060] FIG. 8 illustrates an example of a storage container 110 comprising a metal container body 112 according to a first embodiment of the present invention, where the storage container 110 is formed from a deep-draw press of a sheet metal blank comprising a container bottom wall 115, opposing side walls 116 (a and b), and opposing end walls 118 (a and b). The sheet metal blank is mechanically drawn by the mechanical action of a punch into a forming die that resembles the shape of the storage container. An advantage of deep-drawing over other metal forming processes is the ability to create a leak-proof storage container. The storage container 110 can be fabricated from stainless steel sheet metal having a thickness ranging from 0.5 mm to 2.0 mm, and the thickness can be, for example, 0.55 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, and 1 mm. However, other metals, including, but not limited to, aluminum, can be used to fabricate the metal container body. Preferably, the thickness of the sheet metal blank is approximately 2 mm to provide the necessary structural rigidity for the storage container walls. The storage container 110 shown in FIG. 8 is an example in which a storage container is formed entirely from a deep-drawn process using a single or unitary sheet metal blank. Similar to the storage containers discussed above, opposing side walls 116 (a and b) and end walls 118 (a and b) of the storage container 110 include one or more slots, openings, or vents 120 to allow air flow within the storage container 110. The one or more slots 120 can be cut into the sheet metal blank prior to the deep-drawing process, or alternatively, the one or more slots can be cut or punched into the opposing side walls and / or end walls of the storage container after the deep-drawing process. Similarly, one or more ribs 122 can be punched into the side walls 116 (a and b) and end walls 118 (a and b) of the storage container 110 to reinforce the walls of the storage container, thereby improving the structural integrity or sturdiness of the formed storage container. Similar to storage containers in the art, one or more handles 124 are formed in the side and / or end walls of the storage container.To enable a grabber device of a lift mechanism to engage the rim of the storage container and lift the storage container into the container receiving space of the robotic load handling device, at least a portion of the rim is formed with a lip or flange 126 to allow the grabber device to engage the rim. To create the lip or flange 126, the upper edges of the opposing side walls and / or opposing end walls are turned or bent inward and / or outward. In a specific example of the first embodiment of the present invention, the rims at the upper edges of the opposing end walls of the metal container body are turned outward to form flanges or lips 126 for a grabber device, particularly a gripper element, to engage the rim of the storage container. The lip or flange 126 can have one or more openings (not shown) for receiving a gripper element therein.

[0061] To enable the storage containers of the first embodiment of the present invention to be stacked on top of one another in a storage and retrieval system, the storage containers include one or more stops 128 at the corners of the storage container 110. The container bottom wall of an upper adjacent storage container in the stack abuts or is supported by the one or more stops of the storage container below, thereby preventing the container bottom wall of the adjacent storage container from soiling or crushing the contents of the storage container below in the stack. In the particular embodiment of the present invention shown in Figure 8, the stops 128 are formed by one or more recesses extending inward from the corners into the interior space of the metal container body 112.

[0062] To provide the deep-drawn storage container in the first embodiment of the present invention shown in FIG. 8 with additional structural support to withstand loads when stacked, one or more corner supports 230 can be installed on either the outside or inside of the corners of the storage container 220. In the second exemplary embodiment of the present invention shown in FIG. 9, corner supports 230 are installed on the outside of each of the corners of the storage container 220. Each of the corner supports 230 at the corners of the storage container extends along the entire height or depth of the storage container 220, so that the corner supports 230 withstand the entire weight of the adjacent storage container above in the stack, while the metal container body 212 simply provides the function of storing items within the storage container. In other words, the corner supports 230 provide a support surface for the adjacent storage container in the stack. To provide the necessary structural rigidity, the corner supports are cast, preferably die-cast, from metal. Considering that the thickness of the corner supports is greater than the wall of the metal container body, which is made from a sheet metal blank, other lightweight materials, such as plastic materials, can be used to make the corner supports. As a result, the material of the storage container can be a combination of metal forming the metal container body and plastic corner supports at the corners of the metal container body. The use of plastic corner supports helps keep the overall weight of the storage container low, for example, less than 6 kg, preferably less than 5 kg.

[0063] In a third illustrative embodiment of the present invention shown in FIGS. 10(a and b), one or more of the opposing side walls 316(a and b) and / or opposing end walls 318(a and b) of a deep-drawn metal container body 312 of a storage container 310 may be reinforced with one or more inserts or wall reinforcements 332. As shown in FIG. 10, a wall insert 332 is positioned against each of the opposing end walls 318(a and b) of the metal container body 312 and extends from the container bottom wall 315 to a rim 334 at the upper edge of the metal container body 312. To provide a support surface to facilitate stacking of adjacent storage containers in a stack, the upper edge of the wall insert 332 is directed outward to form a lip 326 at the rim of the metal container body. The outwardly directed lip 326 includes one or more openings 336 to allow a grabber device to engage the rim of the metal container body and lift the storage container from its stack. The wall reinforcement or insert 332 can be cast, preferably die-cast, into the plate to provide the wall of the storage container 310 with the structural integrity necessary to withstand the weight of adjacent storage containers in the stack. Metal, e.g., steel or aluminum, is preferably used to cast the wall reinforcement 332, although other structurally integral materials, such as plastic, can be used to fabricate the wall reinforcement. The wall reinforcement 332 can optionally include one or more recesses 338 adjacent the rim or mouth of the storage container 310 to facilitate stacking of the storage containers; i.e., the one or more recesses 338 in the wall reinforcement provide one or more stops configured to provide a support surface that cooperates with the container bottom wall of an adjacent storage container above in the stack. The lower edge of the wall reinforcement 332 can either abut against the container bottom wall 315 of the metal container body 312 or include one or more tabs 340 that are received in slots in the container bottom wall 315. The walls of the metal container body 312, i.e., opposing side walls 316(a and b) and opposing end walls 318(a and b), slope outward from the container bottom wall 315 such that the metal container body 312 is tapered.The tapered body allows a metal container body to fit inside another metal container body so that multiple storage containers can be stacked neatly within one another, thereby occupying less storage space. In use, the wall reinforcement 332 can be inserted against one or more of the side walls 316(a and b) and / or end walls 318(a and b) of the metal container body 312 to allow one or more storage containers to be supported on top of one another. During transport, the wall reinforcement 332 can be stored separately to allow multiple metal container bodies 312 to be stacked neatly together.

[0064] The metal container body of the first, second, and third embodiments of the present invention is formed from a fully deep-drawn sheet metal blank. In other words, the entire metal container body can be deep-drawn from a single sheet metal blank. The formed deep-drawn structure can be finished or machined to size to form the metal container body. Examples of finishing include, but are not limited to, machining and / or filing the edges of the deep-drawn structure. Full deep-drawing processes suffer from the problem of being bulky products, as the storage container occupies a relatively large portion of storage space when transported. Considering that thousands of storage containers are required in a typical storage system, transporting and storing bulky products is costly and uneconomical. Therefore, there is a need for a storage container comprising a metal container body that does not present a bulky product when transported or stored for use. In comparison to forming the metal body of a storage container by a full deep-drawing process as discussed with reference to FIGS. 8-10(a and b), the metal container body shown in FIGS. 11(a and b)-16 can be made by a two-stage forming process that combines deep-drawing and erecting one or more blanks with foldable side walls. In the exemplary embodiment shown in FIGS. 11(a and b)-20, the metal container body comprises a lower portion, also known as a base, and an upper portion. The terms lower portion and base are used interchangeably in this patent application. The lower portion comprises a deep-drawn base that includes a container bottom wall and opposing side and end walls, forming a shallow base or tray. The deep-drawing process to form the lower portion allows the base of the metal container body to be leak-tight. The upper portion of the metal container body is foldable, in the sense that it can be erected from a folded sheet metal blank or cast into a plate that is pivotally connected together. The sheet metal blank can include one or more fold lines to aid in folding the sheet metal blank to define the side and end walls of the metal container body. An advantage of forming the metal container body by a two-stage forming process is that storage of the metal container body with a top and bottom for transportation efficiently utilizes storage space. For example, multiple bases can be stacked together for transportation.Similarly, multiple sheet metal blanks or plates can be packed flat together and then stood up when in use.

[0065] 11(a) and 11(b) are illustrative embodiments of a metal container body 412 formed by a two-stage forming process in accordance with a fourth embodiment of the present invention. FIG. 11(a) shows a metal container 410 formed from two portions, a lower portion 444 and an upper portion 442, while FIG. 11(b) shows the separate portions 444, 442 joined together to form the box-like structure of the metal container body 412 in accordance with an illustrative embodiment of the present invention, i.e., the lower portion 444 forms the base and the upper portion 442 forms the top of the metal container body. The lower portion 444 is formed by deep drawing or stamping a sheet metal blank to form a shallow base or tray 444 with a container bottom wall 415 and upwardly upstanding opposed base side walls 446(a) and 448(b). The upper portion 442 is formed from two separate sheet metal blanks 450(a and b) that are bent to form opposing upper side walls 452(a and b) and end walls 454(a and b) of the metal container body 412. The first sheet metal blank 450a is bent to form one upper end wall 454a of the metal container body and portions of a pair of opposing upper side walls of the metal container body. The second sheet metal blank 450b is bent to form the other upper end wall 454b of the metal container body and portions of the pair of opposing upper side walls of the metal body. The opposing upper side wall portions are pivotally attached to their respective upper end walls 454(a and b) of the first and second sheet metal blanks 450(a and b) by living hinges 460 or other suitable pivotable connections. The first and second sheet metal blanks 450(a and b) include one or more fold lines to aid in folding the respective sheet metal blanks to form the upper sidewalls and upper end walls of the metal container body. As a result, when the first and second sheet metal blanks are erected and assembled or brought together as shown in FIG. 11(b), they are folded to form two respective C-shaped folds such that the opposing upper sidewall portions from the respective first and second sheet metal blanks 450a and 450b lie in substantially parallel vertical planes. In other words, the C-shaped folds come together to form a tube-like structure that forms the top of the metal container body.The tube-like structure is fed to the lower or base-shaped portion 444, where it is inserted into the shallow base of the lower portion 444 of the metal container body 412 to form a box-like structure with an open end or mouth, as shown in FIG. 11(b). When assembled together, the opposing side walls 416(a & b) of the metal container body 412 comprise upper and lower side wall portions. Similarly, the opposing end walls 418(a & b) of the metal container body 412 comprise upper and lower end wall portions. The opposing side walls 446(a & b) and end walls 448(a & b) of the shallow portion of the metal container body form the lower side wall portion and lower end wall portion, respectively, of the metal container body. The opposing side walls and end walls of the upper portion of the metal container body 412 form the upper side wall portion and upper end wall portion of the metal body. The combination of the deep-drawn shallow base and the C-shaped folds allows at least a portion of the metal container body to be foldable for ease of transportation. The foldable portion of the metal container body comprising the sheet metal blank can also include a plurality of vent holes 462 punched into the sheet metal blank to aid in the circulation of fluid, e.g., air, within the interior space of the metal container body. The thickness of the sheet metal blank for forming the lower and / or upper portions can range from 0.5 mm to 1 mm and can be made of stainless steel, although other metals, such as aluminum, can be used in fabricating the metal container body. The opposing side and end walls of the lower portion can slope outward from the container bottom wall 415 so that the walls 446(a and b), 448(a and b) of the shallow base 444 are slightly tapered. This allows multiple shallow bases or trays 444 to be conveniently stacked together, as shown in FIG. 21 .

[0066] 11(a) and 11(b) also show one or more stops 464 at the corners of the metal container body 412, which are spaced apart and configured to allow vertically adjacent storage containers to be stacked on top of each other. The corner stops 464 are spaced above the container bottom wall 415 to prevent the container bottom wall of an upper adjacent storage container in the stack from crushing the contents of the lower storage container. In the particular embodiment shown in FIGS. 11(a) and 11(b), the one or more stops 464 are formed by punching a recess in the corner of the metal container body, although other means for forming stops are applicable to the present invention. The uppermost edge of at least one of the opposing walls of the rim of the metal container body is directed outward to form a lip 466 for a grabber device of a load handling device to releasably engage and pick a storage container comprising the metal container body from the stack.

[0067] Instead of the upper portion of the metal container body being supported by the lower shallow base by inserting a C-shaped fold into the shallow base as shown in Figures 11(a and b), in a fifth illustrative embodiment of the present invention shown in Figure 12, upper sidewall portions 570(a and b) and upper end wall portions 572(a and b) can be fixedly connected, for example by riveting or welding, to the respective lower sidewall portions (or upwardly upstanding base sidewalls) 546(a and b) and lower end wall portions (or upwardly upstanding end wall portions) 548(a and b) of the shallow base to form a box-like structure. Similarly, the ends of the C-shaped fold are fixedly connected together to form the upper portion of the metal container body, which is in turn fixedly connected to the lower portion of the metal container body 512. Specifically, the ends of the C-shaped fold are connected together by overlapping one end over the other. The ends are fixedly connected together, for example, by welding or riveting the ends together or by using an adhesive.

[0068] An alternative to the embodiment of the metal container body shown in FIGS. 11(a) and 11(b) and 12 is the embodiment shown in FIGS. 13(a) and 13(b), in which the top side walls 670(a) and 672(a) and 672(b) of the metal container body 612 are held together by one or more retainers 674, 676. As with the other embodiments shown in FIGS. 11(a) and 11(b) and 12, the top of the metal container body is foldable in the sense that the top is erected from a folded sheet metal blank. Two sheet metal blanks 650(a) and 650(b) are shown, where each of the two sheet metal blanks 650(a) and 650(b) is bendable to define a side wall 670(a) and an end wall 672(a) and an end wall 672(a) having a length extending along the length of the respective side wall and end wall of the metal container body 612. In other words, each of the two sheet metal blanks 650(a) and 650(b) is bendable to define a substantially L-shaped structure. The two L-shaped structures are brought together to create a tubular structure configured to mount to a lower shallow base. One or more retainers 676 are used to secure the folded sheet metal blanks 650(a and b) together within the walls 646(a and b), 648(a and b) of the shallow base. In the particular embodiment shown in FIG. 13( a), the one or more retainers comprise C-shaped channel tubes 676 at opposite ends of the metal container body for securing the folded sheet metal blanks together. As shown in FIG. 13( b), during assembly of the metal container body, the folded sheet metal blanks 650(a and b) are received within the C-shaped channel tubes 676. To provide additional strength to the metal container body 612, the one or more retainers comprise separate rim portions 674 configured to mount to upper edges of the folded sheet metal blanks 650(a and b) to define the rim of the metal container body 612. The separate rim portions serve the dual purpose of securing the folded sheet metal blank together and providing an engagement surface for a grabber device of a load handling device to engage the rim of the metal container body. One or more of the retainers 674, 676 may be cast to increase the strength of the metal container body.The top portion may be a cast metal plate rather than being formed from bendable sheet metal blanks pivotally connected together.

[0069] In the embodiments shown in Figures 11(a and b), 12, and 13(a and b), the upper sidewall portions are pivotally connected to their respective endwall portions, for example, by living hinges. Instead of having a sheet metal blank with sidewall portions pivotally connected to its respective endwall portions, the opposing sidewalls 770(a and b) and endwalls 772(a and b) of the metal container body 712 can be formed as separate pieces that are assembled together. In a seventh illustrative embodiment of the present invention in Figure 14(a and b), the upper walls 770(a and b), 772(a and b) are formed as separate pieces, for example, by stamping, and then fixedly connected together to form the upper sidewall and endwall portions. The connection of the upper separate wall portions can be made by snap-fit ​​joints. The upper separate portions are also fixedly connected to the lower opposing lower sidewall portions 746(a and b) and lower endwall portions 748(a and b). In a folded or disassembled state, as shown in FIG. 14(a), the separate upper portion can be conveniently folded and placed within the lower shallow base 744, thus allowing the storage container to occupy less storage space for transportation. The separate upper sidewall 770(a and b) and end wall 772(a and b) portions can be stamped from a sheet metal blank and typically have a thickness ranging from 0.5 mm to 1 mm. As with the other embodiments of the invention shown in FIGS. 11(a and b) through 13, the lower portion is formed by deep drawing or stamped from a sheet metal blank. In use, the separate upper sidewall 770(a and b) and end wall 772(a and b) portions can be connected to the lower portion by, for example, snap-fit ​​joints to create a box-like structure, as shown in FIG. 14(b). The upper edge of the shallow base includes engaging portions 750 that snap-fit ​​with corresponding engaging portions of the upper sidewall and end wall portions. 14(a and b), the engagement portions are integrally formed within the side and end wall portions of the lower and upper portions of the metal container body. The upper edge of the upper portion is turned inward to form a lip 766 having one or more apertures or openings in the rim of the metal container body for engaging a grabber device of a load handling device.In use, the separate walls comprising side wall portions 770(a and b) and end wall portions 772(a and b) can be individually secured to the walls of the shallow base 744 such that each opposing side wall of the metal container body comprises a lower side wall portion and an upper side wall portion. Similarly, each opposing end wall of the metal container body comprises a lower end wall portion and an upper end wall portion.

[0070] In yet a further illustrative modification of the seventh embodiment of the present invention shown in FIG. 14(c), separate upper sidewall portions 771(a and b) and upper endwall portions 773(a and b) can be releasably connected together by a releasable latch mechanism to allow for rapid assembly and disassembly of the metal container body 711 from the shallow base 744. The separate portions of the upper portion are also fixedly connected to opposing lower sidewall portions 747(a and b) and lower endwall portions 749(a and b) of the lower portion 744. In the particular embodiment shown in FIG. 14(c) and more clearly shown in FIG. 14(d), the upper sidewall portions 771(a and b) and upper endwall portions 773(a and b) are releasably connected together by cooperation of toggle latches 760 and hooks at distal or opposing ends of the upper sidewall portions and upper endwall portions, respectively. As shown in FIG. 14(c), opposing ends of the upper sidewall portions 771(a and b) include one or more toggle latches 760 configured to cooperate with hooks at opposing ends of the upper endwall portions 773(a and b). Two toggle latches 760 are shown spaced apart at opposing ends of the upper sidewall portions 771(a and b). Assembly of the metal container body involves bringing the ends of the upper sidewall portion and the upper endwall portion together and securely connecting them together with the toggle latches. The present invention is not limited to two toggle latches at opposing ends of the upper sidewall portion; any number of toggle latches can be incorporated into opposing ends of the upper sidewall portion. Similarly, the toggle latches do not necessarily have to be at opposing ends of the upper sidewall portion, but can be at opposing ends of the upper endwall portion. An advantage of releasable latches is that they allow for rapid assembly and disassembly of the metal container body 711. The individual wall portions 771(a and b), 773(a and b) may be formed, for example stamped or cast, from a sheet metal blank as a metal plate.

[0071] In the different examples of metal container bodies shown in Figures 14(a-d), the separate wall sections of the metal container body can be stacked for storage or transport. In the particular embodiment shown in Figure 14(e), multiple separate metal container body sections can be conveniently stacked (780), thereby taking up less storage space compared to their assembled state. Additionally, having separate sections that assemble together during use allows for easy replacement or modification of any one of the separate sections if it is damaged, i.e., providing a spare portion of the metal container body.

[0072] In yet another adaptation of the metal container body shown in Figures 15(a-e), the metal container body 790 is formed by a two-stage forming process comprising a deep drawing process in combination with separate opposing side and end walls. Similar to the embodiment shown in Figures 14(a-e), the upper wall of the metal container body is formed as a separate piece, for example by stamping, and then fixedly connected together to form an upper side wall portion 794 and an upper end wall portion 795. Similar to the other embodiment of the invention shown in Figures 14(a-e), the separate opposing side walls 794 and the upper end wall portion 795 are reinforced to reduce torsional strain of the metal container body 790 when assembled together. Similar to the embodiment shown in Figures 13(a and b), one or more separate rim portions 798, 799 are attached to the upper edges of the upper side wall portion and the upper end wall portion 794, 795 to define the rim of the metal container body 790. 13(a) and 13(b), however, separate rim portions 798, 799 are mounted to each of the upper sidewall portion 794 and the upper end wall portion 795. The rim portions 798, 799 include one or more openings or apertures 810, 811 for engaging a grabber device of a load handling device. The contours of the rim portions 798, 799 cooperate with the upper sidewall portion 794 and / or the upper end wall portion 795 to form elongated hollow portions 802, 805. The elongated hollow portions 802, 805 are located below the one or more openings or apertures 810, 811 in the rim portions, and the elongated hollow portions extend the entire length of the rim portions 798, 799 and are positioned to accommodate the gripper elements of the grabber device. 15(c) and 15(d), upper sidewall portion 794 and upper endwall portion 795 of metal container body 790 are formed from a single skin or sheet of metal blank, optionally formed by stamping a sheet metal blank. Rim portions 798, 799 may likewise be formed from a single skin or sheet metal blank. Upper edges of rim portions 798, 799 are turned inward to form lips 815, 816 having one or more apertures or openings 810, 811 for engaging grabber devices of a load handling device.15(c and d), one or more recesses or bends 803, 804 are formed in the upper edges of the upper sidewall portion 794 and / or upper end wall portion 795, which are positioned to cooperate with one or more apertures or openings 810, 811 in the rim portions 798, 799 when the rim portions are mounted to the upper sidewall portion 794 and / or upper end wall portion 795 to define a cavity for receiving a gripper element of a grabber device such as that shown in FIGS. 5 and 6. Furthermore, the recesses or bends 803, 804 are positioned between a pair of protrusions 800, 801 formed in the upper edges of the upper sidewall portion 794 and / or upper end wall portion 795. Specifically, the recesses or bends 803, 804 and the pair of protrusions 800, 801 on the upper edges of the upper sidewall portion 794 and / or upper end wall portion 795 are designed to fit within the elongated hollow portions 802, 805 of the rim portions 798, 799, as shown in Figure 15(b). Furthermore, the rim portions 798, 799 are configured so that they are clipped or snap-fit ​​onto the exterior of the upper sidewall portion 794 and / or upper end wall portion 795. As shown in Figures 15(c and d), there are two recesses or bends 803, 804 and two pairs of protrusions 800, 801 in the upper edges of the upper sidewall portion 794 and / or upper end wall portion 795 positioned adjacent each corner of the metal container body 790. 15(c and d) are located on the rim portions 798, 799, adjacent each corner of the metal container 790, and are vertically aligned with two recesses or bends 803, 804 in the upper sidewall portion 794 and / or upper end wall portion 795. This arrangement ensures that there is a good connection between the rim portions 798, 799 and the upper sidewall portion 794 and / or upper end wall portion 795 over the length thereof, particularly around the area that interacts with the gripper device.To improve the structural integrity of the box-like structure of the metal container body and enable the upper sidewall portion and upper end wall portion to be secured together, one or more flanges 806, 807 are formed on opposing ends of the upper sidewall portion 794 and the upper end wall portion 795. The flange 807 of the upper end wall portion 795 is configured to rest on the adjacent flange 806 of the upper sidewall portion 794 when brought together with the lower portion 791 of the metal container body to form the box-like structure. For example, the flange 807 of the upper end wall portion 795 is configured to rest on the adjacent flange 806 from the upper sidewall portion 794. This is shown in FIG. 15(e). Each of the flanges of the adjacent upper sidewall portion or upper end wall portion extends across the corners of the metal container body to reinforce the corners. Various fasteners known in the art can be used to secure the upper sidewall portion 794 and end wall portion 795 together at the corners of the metal container body using their respective flanges. These include, but are not limited to, welding, e.g., spot welding, riveting, and / or the use of adhesives. In certain embodiments of the invention, the flanges 806, 807 of the upper sidewall portion 794 and the upper end wall portion 795 are fastened or connected together by a process called mechanical clinching. Clinching is similar to riveting, but does not require separate rivets and involves plastically deforming the sheet metal using a special punch and die to create a physical interlock between the sheet metal layers. To further improve the structural integrity of the box-like structure, the rim portion 798 mounted on the upper end wall portion 795 also includes rim flanges 812 at each corner that rest on top of each flange 807 of the upper end wall portion 795.

[0073] To enable the gripper elements of the grabber device to be properly aligned with the apertures or openings 810, 811 in the rim portions of the storage container, the metal container body includes guides 796 at each corner of the box-like structure of the metal container body 790, extending vertically from the top edge at least partially along the height of the box-like structure to accommodate guide or locating pins of the grabber device. As discussed above with reference to FIG. 6 , the guides 796 are shaped to cooperate with the guide or locating pins of the grabber device to properly align the gripper elements 62 with the openings 810, 811 in the rim portions 798, 799 of the storage container. The guides 796 at the corners of the metal container body are formed by elongated vertical recesses in the flanges 807 of the upper sidewall portions and / or upper end wall portions 794, 795. The elongated vertical recesses 796 may be formed by one or more bends in the sheet metal of the upper sidewall portions 794 and / or upper end wall portions 795. In a particular embodiment of the invention, an elongated vertical recess 796 is formed in a flange 807 of the upper end wall portion 795, as shown in Figure 15(d). A corresponding elongated recess 813 is formed in a rim portion 798 mounted to the upper end wall portion 795, which is shaped to cooperate with the elongated vertical recess 796 formed in the flange 807 of the upper end wall portion 795, as shown in Figure 15(d). The elongated vertical recess 796 in the flange 807 of the upper end wall portion 795 is configured to rest on the flange 806 of the upper side wall portion 794 at a corner of the box-like structure of the metal container body 790 when the upper side wall portion 794 and the upper end wall portion 795 are brought together, as shown in Figure 15(e). Flanges 806, 807 resting on the upper side wall portion 794 and upper end wall portion 795, together with elongated vertical recesses 813 resting on flanges 812 of rim portion 798, provide three overlapping layers at the corners of metal container body 790. This in turn reinforces the corners of metal container body 790 to withstand loads from one or more storage containers positioned above, particularly when a storage container comprising the metal container body is placed in a stack of storage containers.Thus, from the three-part corner configuration shown in Figure 15(e), there is rigidity through the corners of the metal storage container 790. The edges 797 of the rim portions at the corner portions of the metal container body are contoured to wrap around the flanges 806 of the upper sidewall portion, thus improving the connection of the rim portion to the upper sidewall portion.

[0074] In the ninth embodiment of the metal container shown in FIG. 16 , the metal container body 818 includes a deep-drawn base 820, an upper sidewall portion 822, and an upper end wall portion 824. Rim portions 823, 825 are mounted on each of the upper sidewall portion 822 and upper end wall portion 824. The deep-drawn base 820 includes an embossed pattern in the container bottom wall to increase the base's rigidity and improve grip against underlying rollers in the conveying system. In FIG. 16 , the embossed surface includes a hexagonal pattern, but any type of pattern can be used, such as a square pattern as shown in FIG. 17( b). In contrast to the metal container body shown in FIG. 15 , in this embodiment, the flange 821 of the rim portion 825 mounted on the upper end wall portion 824 extends vertically from the top of the corner of the metal container body 818 to the deep-drawn base 820. As shown in Figure 16, this means that both flange 821 of rim portion 825 and flange 827 of upper end wall portion 824 provide increased rigidity along the entire vertical length of the corners of metal container body 818. Figure 16 also shows that the metal container includes a notch 819 on each of the upper side wall portions 822. Notch 819 is surrounded and reinforced by rim portion 823 to provide increased rigidity, and rim portion 823 extends downward on either side of notch 819, so that rim portion 823 has a vertical height that is greater than the height of notch 819. By having a notch 819 in each of the upper side wall portions 822, metal container body 818 can be used to hold shipping totes.

[0075] 16 also includes corner pieces or feet 826 that fit into the corners of the deep drawn base 820. The corner pieces 826 allow the shipping tote to sit within the metal container body 818 at a height appropriate for the shipping tote machine.

[0076] In contrast to the metal storage container shown in FIGS. 15 and 16 , which includes four rim portions, the metal storage container 828 shown in FIG. 17 includes two rim portions 834 mounted on each of the upper end wall portions 836. The rim portion 834, shown in more detail in FIG. 17( c), includes an elongated central portion 837 and two recesses 838 on either side of the elongated central portion. The two recesses 838 allow a gripper device to engage the metal storage container 828. The rim portion 834 extends into a protruding lip 849, so that when the rim portion 834 is mounted on the upper end wall portion 836, the protruding lip 849 serves to support the bottom container wall of the base 830 of an adjacent storage container above in the stack. Such adjacent storage containers are also supported by a top edge hem 831 at the upper edge of the upper end wall portion, which will be discussed shortly. Rim portion 834, although shown as one component in Figure 17(c), may similarly be formed as two components joined in the center of elongated central portion 837 and spot welded together.

[0077] Rim portion 834 is configured to fit over top edge fold 831 at the upper edge of upper end wall portion 836. Top edge fold 831 is approximately 20 mm wide and is configured to engage elongated central portion 837 of rim portion 834 and allow access for a gripper device to engage metal storage container 828 through recess 838 in rim portion 834. Rim portion 834 is fitted and secured over top edge fold 831 using spot welds. Spot welds may also be used to secure other portions of the metal storage container together; for example, as shown in FIG. 17( a), top end wall portion 836 is attached to base 830 by three spot welds 833 and upper side wall portion 832 is attached to base 830 by four spot welds, although the upper side wall portions and / or upper end wall portions may be connected by any number of spot welds, for example, 2, 5, 6, 7, 8, or 9 spot welds per side. Specifically, the upper end wall portion 836 and the upper side wall portion 832 are attached to base side wall and end wall portions that upstand above the base.

[0078] The upper sidewall portion 832 and the upper end wall portion 836 include ribs or beaks 835 formed from molding metal. The ribs or beaks 835 are located near the base of the upper sidewall portion 832 and the upper end wall portion 836. The ribs or beaks 835 increase the rigidity of the upper sidewall portion 832 and the upper end wall portion 836. As shown in FIG. 17( a), the ribs or beaks 835 are symmetrically positioned along the length of the upper sidewall portion 832 and the upper end wall portion 835. The ribs or beaks 835 minimize movement of the upper sidewall portion 832 and the upper end wall portion 836 when assembled into a box-like structure. As shown in FIG. 17( a), three ribs or beaks 835 are located on the upper end wall portion 836 and seven ribs or beaks are located on the upper sidewall portion 832. There may be any number of ribs or peaks in the upper sidewall portion 832 and upper end wall portion 836, for example, there may be 4, 5, 6, 8, or 9 ribs or peaks on each upper sidewall portion 832 and / or upper end wall portion 836.

[0079] Each upper sidewall portion 832 and upper end wall portion 836 of the metal container body 828 includes a flange 840a, 840b at each corner. As shown in FIG. 17(d), when the upper sidewall portion 832 and upper end wall portion 836 are positioned within the base 830 to form the box-like structure 828, each flange 840a, 840b overlies or underlies another adjacent flange. FIG. 17(d) specifically shows flange 840b of upper sidewall portion 832 positioned inside flange 840a of upper end wall portion 836. This structure, with one flange resting on top of the other, reinforces the corner and provides greater vertical structural rigidity. In contrast to the corner shown in FIG. 15(e), the corner in this embodiment includes two pieces instead of three. This provides a cost advantage over the embodiment shown in FIG. 15. The upper side wall portion 832 and the upper end wall portion 836 are connected to the base 830 by placing the upper side wall 832 or upper end wall 836 inside the base side wall or base end wall 841 and spot welding the two respective walls together, as shown in FIG. 17(e).

[0080] Additionally, metal storage container 828 includes holes in one or more flanges of the upper side or end wall portion. As shown in FIG. 17( a), holes 839 are located in each of flanges 840 a of upper end wall portion 836. Alternatively or in addition, one or more holes may also be located in each of flanges 840 b of upper side wall portion 832. One or more holes 839 can be used as a positioning tool to allow metal storage container 828 to be accurately and repeatedly positioned in the same location, if desired.

[0081] This embodiment uses bar codes (not shown) located on the exterior of the metal storage container to help identify the location and alignment of the container in, for example, a shipping tote machine. This is an alternative to using corner pieces or feet as used in the embodiment of Figure 16.

[0082] The eleventh embodiment of a metal storage container 842 shown in FIG. 18 is similar to the embodiment of FIG. 17 . However, the embodiment shown in FIG. 18 further includes a recess 843 positioned on each upper sidewall portion 845. The recess 843 is C-shaped and is sized and shaped to allow an alignment tool to be inserted into the recess 843, thus ensuring accurate alignment of the metal storage container in, for example, a shipping tote machine. Like the embodiment shown in FIG. 16 , the metal storage container 842 of the eleventh embodiment also includes a notch 847 in each of the upper sidewall portions 845. By having the notch 847 in each of the upper sidewall portions 845, the metal container body 842 can be used to hold a shipping tote.

[0083] 14-18 illustrate different embodiments of metal storage containers having upper sidewall portions and upper endwall portions that are separate from the base. Alternatively, upper sidewall portions 870(a and b) and upper endwall portions 872(a and b) of a metal container body 860 can be pivotally attached to corresponding lower sidewall portions 846(a and b) and lower endwall portions 848(a and b) of a shallow base or tray 844 by hinges 880, e.g., living hinges, as shown in a twelfth illustrative embodiment of the invention in FIG. 19(a and b). In use, the upper sidewall portions 870(a and b) and upper endwall portions 872(a and b) are rotated about their respective pivotable connections 880, as shown in FIG. 19(b), such that adjacent ends of the upper sidewall portions 870(a and b) and upper endwall portions 872(a and b) are joined to form a box-like structure. The joints between adjacent ends of the upper side wall portions 870(a & b) and the upper end wall portions 872(a & b) may be by snap-fit ​​joints, welding, riveting, or even the use of adhesive. As with the other embodiments of the invention discussed above, the upper edges of the side and end walls at the rim of the metal container body are turned inward to form a lip or flange 866 for releasably engaging a grabber device.

[0084] Alternatively, as shown in the thirteenth exemplary embodiment of the present invention in FIGS. 20(a) and 20(b), the opposing ends of upper sidewall portions 970(a) and upper endwall portions 972(a) and 972(b) can be joined together at the corners of the metal container body 912 by one or more corner struts 930. The corner struts 930, which can be cast, provide structural integrity to the walls of the metal container body 912 to prevent buckling when stacked with other storage containers in a grid framework structure. In the assembled state shown in FIG. 20(b), the sidewalls of the metal container body 912 comprise lower sidewall portions 946(a) and upper sidewall portions 970(a) and upper endwall portions 970(a) and upper endwall portions 972(a) and upper endwall portions 972(a) and upper endwall portions 972(b).

[0085] As with the other embodiments of the invention shown in Figures 14(a and b) through 20, the base side and end wall portions of the shallow base slope outward from the container bottom wall so that multiple metal container bodies can be stacked on top of each other for ease of transportation, as shown in Figure 21. In the twelfth and thirteenth embodiments shown in Figures 19 and 20, having the upper side and end wall portions pivotally attached to their respective lower side and end wall portions of the shallow base prevents any of the parts of the metal container body from being lost during transport and allows the metal container to be easily assembled when in use.

[0086] In contrast to forming the metal container body from a deep-drawn base and one or more folded sheet metal blanks, the base and top of the metal container body can be formed from one or more patterned sheet metal blanks, as shown in the fourteenth and fifteenth exemplary embodiments of the present invention shown in Figures 22 and 23. For storage of food items, one or more flanges can be bent or folded at the edges of the sheet metal blank so that, when erected, the flanges hold the side and end walls together in an upright position and serve to seal the joints between adjacent side and end walls of the metal container body to prevent fluid leakage from the metal container body. As an alternative to, or in combination with, providing flanges at the joints between adjacent walls (side and end) of the metal container body, the interior space within the metal container body can be provided with a polymer liner or inner container to contain any leakage from the contents of the storage container.

[0087] In a fourteenth exemplary embodiment of the present invention shown in Figures 22(a and b), a metal container body 1012 is formed from two sheet metal blanks 1050 (a and b) that are erected to form the container bottom wall 1015, side walls 1016 (a and b), and end walls 1018 (a and b) of the metal container body 1012. Erecting the metal container body 1012 from one or more sheet metal blanks 1050 (a and b) has the advantage that the metal container body can be packed flat for ease of transportation and storage. In the particular embodiment shown in Figure 22(a), the metal container body 1012 is formed from a main section 1050a that forms the container bottom wall 1015 and opposing side walls 1016 (a and b) of the metal container body 1012 and separate end plates 1050b that form the end walls 1018 (a and b) of the metal container body 1012. The main section 1050a of the sheet metal blank includes a fold line 1052, shown as a dashed line, running perpendicular to the longitudinal direction of the main section 1050a. In use, the main section 1050a of the sheet metal blank is folded along the fold line 1052 to create a container bottom wall 1015 and opposing side walls 1016(a and b) of a metal container body 1012 having opposite open ends, i.e., the opposing side walls are folded substantially perpendicular to the container bottom wall. As shown in FIG. 22(b), an end plate 1050b is then used to cover the opposite open ends to form a box-like structure. An edge or distal end of the main section 1050a and / or end plate 1050b can be folded to create a flange 1054 for securing the end plate 1050b to the folded main section 1050a of the sheet metal blank, i.e., for securing the end plate 1050b to the side walls 1016(a and b). 22, opposing edges of the main section of the sheet metal blank are extended to form flanges 1054. The end plate 1050b can be secured to the flanges 1054 of the sheet metal blank 1050a by welding, using adhesive, or other fastening means.In the particular embodiment shown in FIG. 22(b), the end plate 1050b is fixedly attached to the flange 1054 of the sheet metal blank 1050a by riveting. As with the other embodiments of the invention described above, the main section 1050a and / or the end plate 1050b can include one or more vent holes 1020, which can be punched into their respective sheet metal blank 1050a or end plate 1050b to create the vent 1020 and / or handle. At least one edge or end of the main section and end plate of the sheet metal blank can be turned inward or outward to create a lip 1064 in the rim around the periphery of the assembled box-like structure, as shown in FIG. 22(b). As with the other embodiments of the invention, the lip 1064 in the rim allows a grabber device of a load handling device to engage the metal container body when lifting the storage container from the stack.

[0088] Alternatively, the metal container body 1112 can be formed from a single piece, more specifically, from a single sheet metal blank 1150, as in the fifteenth illustrative embodiment shown in FIGS. 23(a) and 23(b). As shown in FIG. 23(a), the sheet metal blank 1150 includes a central section forming the container bottom wall 1115 and opposing side wall 1116(a) and end wall 1118(a) and end wall 1118(a) sections attached to the central section 1115, for example, by living hinges. Erecting the metal container body includes folding the opposing side wall 1116(a) and end wall 1118(a) and end wall 1118(a) sections substantially perpendicular to the container bottom wall section 1115 to form a box-like structure as shown in FIG. 23(b). The sheet metal blank 1150 can include fold lines 1152 to aid in folding the opposing side wall and end wall sections. The edges of the side walls and / or end walls and / or container bottom wall portions can be folded to create flanges for joining the walls of the metal container body together and provide a leak-proof container body. Alternatively, the interior space within the metal container body can include a polymer liner or inner container to contain any leaks from the storage container. One or more retainers can be used to hold the opposing side walls and end walls in an upright position. Similarly, the upper edges or ends of the opposing side walls and end walls can be oriented, for example, inward or outward, to form a lip 1164 on the rim of the box-like structure. The rim includes one or more openings 1160 to allow a grabber device to engage the metal container body. As with other embodiments of the metal container body, one or more vent holes 1120 can be cut into the sheet metal blank, for example, by stamping or other means, to allow air to circulate within the metal container body.

[0089] In all of the embodiments described with reference to Figures 8-23 that utilize a sheet metal blank to create a metal container body, e.g., by deep drawing or folding the sheet metal blank, the sheet metal blank can be coated with a laminated polymer lining. This is particularly important when the contents of the storage container include food items to prevent contamination of the food items due to exposure to the metal container body. Additionally, the sheet metal blank can be corrugated, e.g., by stamping, by forming one or more ribs in the sheet metal blank to improve the structural integrity of the erected metal container body.

[0090] In another exemplary embodiment of the present invention, the metal container body 1212, including the container bottom wall 1215, opposing side walls 1216 (a and b), and end walls 1218 (a and b), can be cast as a single unit. For example, the metal container can be die-cast or, alternatively, cast by an investment casting process. In a sixteenth exemplary embodiment of the present invention shown in FIG. 24, the metal container body 1212 is die-cast as a single unit. While not providing a collapsible storage container like the other embodiments discussed above, casting the metal container body as a single unit provides improved strength in a single piece to prevent buckling of the walls of the metal container body when placed in a stack. The metal container body can be cast from aluminum having a wall thickness of approximately 1 to 1.5 mm. However, other lightweight metals can be used to cast the metal container body. Another advantage of casting the metal container body is that it provides a leak-proof container to prevent leakage of fluid from the storage container. The vent holes 1220 can be formed in-situ when the metal container body is cast, or alternatively, the vent holes can be machined into the walls of the metal container body after it has been cast. The vent holes 1220 can be located at a predetermined height above the container bottom wall to provide a leak-proof base to capture any spills. Optionally, one or more ribs 1222 can be cast into the walls (side and end walls) of the metal container body 1212 to improve the structural integrity of the metal container body to withstand loads when in a stack.

[0091] In the different embodiments of the present invention described above, the walls of the metal container body are generally solid, meaning composed of a solid material, and may be coated or laminated to ensure that the interior surface of the metal container body is food-safe. One or more wall reinforcements and / or inserts and / or corner supports may be incorporated into the metal container body to improve the structural integrity of the storage container. In still further exemplary embodiments of the present invention, the walls of the metal container body may be hollow to incorporate a secondary filler material. In the seventeenth exemplary embodiment of the present invention shown in FIG. 25, the opposing side walls 1316 (a and b) and end walls 1318 (a and b), and optionally the container bottom wall 1315, are hollow. The hollow space within the walls of the metal container body may be filled with a filler material to improve the properties of the metal container body 1312. For example, the filler material may be a polymer foam that provides sound-attenuating acoustic properties to the storage container. Optionally, the filler material may be fire-resistant. Exemplary fire-resistant materials that are lightweight and fire-resistant include, but are not limited to, vermiculite. Filler materials can also improve the structural properties of storage containers to withstand loads when held in stacks. Although not shown in FIG. 25, one or more ribs can be formed in the walls of the storage container to improve the structural integrity of the storage container. Joints between adjacent side and end walls can be secured together by welding, adhesives, rivets, or simply tongue-and-groove joints. The container bottom, side, and end walls can be separate pieces that are assembled together during use to facilitate transportation.

[0092] When the contents of a storage container are food items, it is essential that the food items be stored in a container that meets food safety standards. There are limited types of metals that can be used to fabricate a metal container body that will meet food safety standards. These include various stainless steel materials, such as 304 stainless steel. However, fabricating a metal container body from stainless steel presents the problem that the metal is less dense and generally more expensive than other types of metal, such as lower-grade steel or aluminum. As a result, the walls of a metal container body will be relatively thin compared to its corresponding plastic variant of similar weight in the industry. The area of ​​a storage container that is susceptible to fire is the exterior surface of the storage container. Because the metal container body is fire-resistant, it can function as a fire-resistant body that forms a non-combustible enclosure to prevent or limit the penetration of fire into the interior space of the storage container. Because the metal container body can function as a non-combustible enclosure and meet food safety standards for storing food items, the fire-resistant body can include a liner formed from a food-grade material. Examples of food-grade materials include, but are not limited to, various food-grade plastic materials and cellulose-based materials such as paper or cardboard. Paper or cardboard liners can be impregnated or coated with a food-safe wax to make the liner moisture-resistant. At least a portion of the interior surface of the fire-resistant body comprises a liner 1420, 1422 formed from a food-safe or food-grade material, in that the height of the liner 1420 extends partially the full height of the metal container body 1412, as shown in FIGS. 26 and 27, or partially the full height of the liner 1422 of the metal container body 1412, as shown in FIGS. 28 and 29. The use of liners 1420, 1422 compatible with the storage of food items allows different materials to be used for the fire-resistant body. In certain embodiments described above, the fire-resistant body 1412 can comprise metal, or other fire-resistant materials can be used to construct the fire-resistant body, including various ceramic materials and various fire-resistant plastic materials, such as plastic materials with fire-resistant additives.This fire-resistant body can comprise a lower density material, but have the same structural integrity and load-bearing capacity as current plastic-based storage containers. As a result, the walls of the fire-resistant body can be thicker, thereby providing the walls of the storage container with sufficient load-bearing capacity to support the weight of multiple storage containers in a stack.

[0093] In a specific embodiment of the invention shown in FIG. 26 , the fire-resistant body comprises a metal container body 1412 having a bottom wall 1415 and upwardly upstanding, opposing side walls 1416 a, 1416 b and end walls 1418 a, 1418 b. The metal container body 1412 is partially lined with a liner 1420. In a specific embodiment of the invention shown in FIG. 27 , the liner 1420 is a tray or shallow base formed as an insert in the metal container body 1412. The tray 1420 is formed from a food-grade material and is leak-proof to prevent leakage of juices from food items such as meat. Various examples of forming the leak-proof liner exist. These include, but are not limited to, blow molding or thermoforming a one-piece liner, where the liner comprises a food-grade plastic material. If the liner comprises a cellulose-based material such as paper or cardboard, the liner can be formed from a foldable sheet blank impregnated or coated with a wax material. The height of the liner need not extend the entire height of the metal container body, but can extend partially to the entire height of the metal container body. In the example shown in FIG. 27, the height of the tray 1420 extends half the height of the metal container body 1412. This is considered acceptable when food items stored in the storage container contact only the bottom wall of the storage container and partially along the opposing side and end walls, and / or when it is only necessary to prevent juices from the food items from leaking and contaminating other food items in nearby storage containers. However, this is not to say that the liner can extend the entire height of the metal container body. FIGS. 28 and 29 show an example in which the liner 1422 extends the entire height of the metal container body 1412. Again, the liner 1422 functions as an insert placed inside the metal container body, as shown in FIG. 28.

[0094] Having a paper or cardboard-based liner allows the liner to be disposable, allowing different types of food items to be stored in the metal container body and limiting the need to continually clean the interior surface of the storage container. When a storage container comprises a metal container body, especially a low-grade steel, using water to clean the storage container tends to corrode or rust the metal container body, rendering it unusable for storing food items. Using a liner made of a food-grade material eliminates the need to clean the metal container body, thereby extending the life of the metal container body. While preferred embodiments of the present invention have been described in detail above, it should be understood that various modifications of the storage container, including different features described above and different combinations of features described in connection with different embodiments, are applicable within the scope of the present invention as defined by the claims.

[0095] Further features of the present invention may be described with reference to the following numbered clauses:

[0096] Clause 1: A storage and retrieval system comprising a track system and a plurality of stacks of storage containers, wherein the storage containers (828) for storing one or more items, the track system comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks running transversely to the first set of parallel rails or tracks in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces or grid cells, the plurality of stacks being located below the track system, each stack of the plurality of stacks of storage containers occupying a single grid space or grid cell, the first fire-retardant storage container comprising a container bottom wall and upwardly upstanding opposing side walls and end walls disposed in a box-like structure having an open end for receiving one or more items within the box-like structure, 1. A storage container comprising a fire-resistant container body forming a non-combustible enclosure, wherein at least a portion of an interior surface of the fire-resistant container body comprises a liner formed from a food-grade material.

[0097] Clause 2: A storage container as described in clause 1, wherein the fire-resistant container body is a ceramic container body.

[0098] Clause 3: A storage container as described in clause 1, wherein the fire-resistant container body is a plastic container body.

[0099] Clause 4: A storage container according to any one of clauses 1 to 3, wherein at least one of the upwardly upright opposing side walls and / or end walls is detachable.

[0100] Clause 5: A storage container according to any one of clauses 1 to 4, wherein the liner comprises a food-grade plastic material and / or a cellulose-based material.

[0101] Clause 6: A storage container according to clause 5, wherein the cellulose-based material is coated or impregnated with a waxy material.

[0102] Clause 7: A storage container according to clause 6, wherein the cellulose-based material is paper or cardboard.

[0103] Clause 8: A storage container according to clause 7, wherein the liner is formed from a folded paper or cardboard blank.

[0104] Clause 9: A storage container according to any one of clauses 1 to 8, wherein the liner is disposable.

[0105] Clause 10: A storage container according to any one of clauses 1 to 9, wherein the liner is a shallow base or tray.

[0106] Clause 11: The storage container of any one of clauses 1 to 10, wherein the liner is a leak-proof container.

[0107] Clause 12: A storage container as described in clause 11, wherein the leakproof container is a one-piece thermoformed container.

Claims

1. In a storage and retrieval system comprising a track system and a plurality of stacks of storage containers, a storage container (828) for storing one or more items, comprising: the track system comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks running transversely to the first set of parallel rails or tracks in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces or grid cells; the plurality of stacks are located below the track system; Each stack of the plurality of stacks of storage containers occupies a single grid space or grid cell, the storage container comprising a metal container body (829) formed as a single, unitary piece and comprising: a base (830) having a container bottom wall (814) to define a tray and upwardly upstanding base side and end wall portions (841); and a separate upper portion having upper side and end wall portions (832, 836) extending upwardly from and connected to the respective base side and end wall portions (841) of the base to form a box-like structure having an open end for receiving the one or more items within the box-like structure.

2. The storage container of claim 1 , wherein the base (830) of the metal container body is formed from a deep-drawn sheet metal blank.

3. 3. The storage container of claim 1 or 2, wherein the metal container body comprises a rim portion (834, 798) extending around at least a portion of the periphery of the open end of the box-like structure, the rim portion comprising one or more openings or recesses (838, 811) for engagement with a grabber device of a load handling device.

4. 4. The storage container of claim 3, wherein the rim portion (834, 798) comprises a protruding lip (849, 816) directed inward or outward from the upper side wall portion and the upper end wall portion (836, 795) for supporting the container bottom wall of an adjacent storage container above in a stack.

5. 5. A storage container according to claim 3 or 4, wherein the rim portion (834, 798, 799) is separately connected to the upper side wall portion and / or the upper end wall portion (836, 794, 795).

6. A storage container according to any one of claims 1 to 5, wherein the upper side wall portion and / or the upper end wall portion (832, 836) comprises ribs or beaks (835).

7. The storage container of any one of claims 1 to 6, wherein each corner of the metal container body comprises a plurality of overlapping layers.

8. A storage container according to any one of claims 1 to 7, wherein the upper side wall portion (794) is separately secured to the upper end wall portion (795).

9. 9. The storage container of claim 8, wherein the upper side wall portion (794) and / or the upper end wall portion (795) each comprises at least one flange (806, 807) for fixedly connecting the upper side wall portion to the upper end wall portion.

10. 10. The storage container of claim 9, wherein each flange (806, 807) is configured to either overlie or underlie the adjacent flange.

11. 11. A storage container according to claim 9 or 10, wherein the flanges (806, 807) of the upper side wall portions and / or the upper end wall portions (794, 795) are fastened together by a mechanical clinching process.

12. 7. The storage container of claim 1, wherein at least one of the upper side wall portions is releasably connected to at least one of the upper end wall portions by a snap-fit ​​joint and / or a toggle latch (760).

13. The storage container of any one of claims 9 to 11, further comprising guides (796) at each corner of the storage container for alignment of grabber devices of the load handling device.

14. 14. The storage container of claim 13, wherein the guide (796) is formed by an elongated vertical recess in the flange (807) of the upper side wall portion and / or the upper end wall portion.

15. 15. The storage container of claim 1, wherein the metal container body of the storage container is provided with a plurality of stop portions (128) for supporting the container bottom wall of an adjacent storage container in the stack, the stop portions (128) projecting inward into the mouth of the storage container and positioned at diagonally opposite corners of the storage container, the plurality of stop portions being spaced above the container bottom wall to prevent one or more items in the storage container from being soiled by the container bottom wall of an adjacent storage container above in the stack.

16. The storage container of any one of claims 1 to 15, wherein the base (820) comprises one or more patterns embossed into the container bottom wall.

17. The storage container of any one of claims 1 to 16, wherein the storage container comprises a liner (1420, 1422) formed from a food-grade material.

18. 18. The storage container of claim 17, wherein the liner comprises a food-grade plastic material and / or a cellulose-based material.

19. 20. The storage container of claim 18, wherein the cellulose-based material is coated or impregnated with a waxy material.

20. 20. The storage container of claim 19, wherein the cellulose-based material is paper or cardboard.

21. 21. The storage container of claim 20, wherein the liner is formed from a folded paper or cardboard blank.

22. The storage container of any one of claims 17 to 21, wherein the liner is disposable.

23. A storage container according to any one of claims 17 to 22, wherein the liner is a shallow base or tray.

24. A storage container according to any one of claims 17 to 23, wherein the liner is a leak-proof container.

25. 25. The storage container of claim 24, wherein the leak-proof container is a one-piece thermoformed container.

26. 10. A kit for assembling the storage container of claim 1, comprising: i) a base (830) formed as a single, unitary piece and having a container bottom wall and upwardly upstanding base side and end wall portions (841) for defining a tray; ii) a separate upper portion comprising an upper sidewall portion (832) and an upper endwall portion (836); A kit comprising:

27. The kit comprises:

27. The kit of claim 26, further comprising: iii) two or more rim portions (837, 798, 799) separately connectable to said upper side wall portion (794) and / or said upper end wall portion (836, 795).

Images