Storage systems and storage containers

Abstract

A storage container (828) for storing one or more items in a storage and retrieval system comprises a track system comprising first and second sets of horizontal parallel tracks forming a grid pattern including a plurality of grid spaces, and a storage container stack located below the track system, each stack occupying a single grid space. The storage container comprises a metal container body (829), the metal container body comprising a base portion (830) formed as a single unit body and having a container bottom wall (814) and an upwardly upright base side wall portion and an end wall portion (841) to form a tray, and a separate upper portion having an upper side wall portion (832) and an end wall portion (836) extending upward from each base side wall portion and end wall portion (841) and connected thereto to form a box-shaped structure having an open end to accommodate one or more items within a box-shaped structure.

Description

Technology Field

[0001] The present invention relates to a storage system comprising a load handling device operating on a track located on a grid framework structure to handle storage containers stacked on a grid framework structure, and to a storage container for use in such a storage system. Background Technology

[0002] Some commercial and industrial activities require systems capable of storing and retrieving many different products. One known type of system for storing and retrieving goods in multiple product lines involves arranging storage containers (also known as boxes or totes) in a stacked manner, with the stacks arranged in rows. Storage containers are removed from the stack and accessed from above by a load handling device, eliminating the need for a passageway between the rows, and thus a large number of containers can be stored in a given space.

[0003] WO2015 / 185628A describes a storage and order processing system in which a stack of storage containers is placed within a grid framework structure. The containers are accessed by a load handling device that operates on a track located at the top of the grid framework structure.

[0004] Storage containers of such storage systems are generally made of thermoplastic materials and can 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 system described above is that the containers can be highly flammable, and considering that the storage system may contain hundreds or thousands of containers, the containers pose a significant risk in the event of a fire.

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

[0007] The present invention mitigates the above problems by manufacturing the storage container from metal. Compared to plastic materials, using metal in the manufacture of the storage container allows the storage container to withstand much higher temperatures before decomposition and emits very little or no toxic smoke in the event of a fire. Additionally, a larger portion of the storage container material is easily recyclable, making the storage container of the present invention more environmentally friendly. Using metal in the manufacture of the storage container provides a rigid structure that allows the storage containers to be stacked vertically 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, the storage and retrieval system comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks positioned transversely to the first set of parallel tracks in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces or grid cells, and a plurality of storage container stacks positioned below the track system, each of the plurality of storage container stacks occupying a single grid space or grid cell. A storage container comprises a metal container body, wherein the metal container body comprises a base portion formed as a single monolithic body and having a container bottom wall, an upwardly standing base side wall portion, and an end wall portion to form a tray, and a separate upper portion having an upper side wall portion and an end wall portion extending upward from each base side wall portion and end wall portion of the base portion and connected thereto to form a box-shaped structure having an open end for accommodating one or more articles within a box-shaped structure.

[0008] According to the present invention, a plurality of storage container stacks are provided, and each storage container of the plurality of storage container stacks comprises a metal container body including a container bottom wall and upwardly upright mutually opposing side walls and end walls. Each of the plurality of storage container stacks is located under a track system and occupies a single grid space or grid cell. The metal container body may form an integral part of the storage container in that the metal container body is a storage container, or it may be a separate part of the storage container in that the metal container body forms a part of the storage container, such as a metal lining.

[0009] Typically, storage containers in the industry are formed from plastic materials as a single monolithic body. Considering that thousands of storage containers are required in a typical storage and retrieval system, the storage containers exhibit a significant volume during transport, which ultimately results in substantial transportation costs. Making storage containers fire-resistant and easily transportable at a low cost is a difficult task in the industry. The present invention alleviates this problem by providing a metal container body, wherein each metal body of a plurality of storage containers has a base portion formed as a single monolithic body and a separate upper portion connected to the base portion to form a box-shaped structure. For the disassembly of the metal container, the upper portion can be separated from the base portion. This makes packaging the storage container easier, and upon disassembly, the metal container occupies a smaller volume than when assembled. In particular, the base portion is stackable due to the structure of the container bottom wall forming a tray, the upwardly standing base side wall portion, and the end wall portion. Therefore, when disassembling the metal container, at least a portion of the metal container body can be stacked.

[0010] One or more robotic load handling devices operating on a track system and including a container receiving space can lift and lower storage containers, and thus, when positioned above at least one stack among a plurality of storage container stacks occupying a grid cell, the lifting mechanism is configured to lift at least one storage container from at least one stack among the plurality of storage container stacks into the container receiving space. Optionally, the lifting mechanism includes a grabber device, which, when in use, is configured to releaseably grasp a storage container and lift the storage container from at least one stack among the plurality of metal storage container stacks into the container receiving space. To enable the grabber device to releaseably grasp a storage container, the grabber device optionally includes at least two gripper elements capable of being coupled with a perimeter rim surrounding an open end of a storage container. Preferably, the rim includes one or more openings or recesses, so that each of the one or more gripper elements can be received into the one or more openings or recesses of the rim of the storage container. Preferably, a periphery, also referred to as a rim portion, extends around at least a portion of the periphery of the open end of the box-shaped structure, and the rim portion includes one or more openings or recesses for engaging with the grabber device of the load handling device. The rim portion may be located at the upper edge of the upper sidewall portion and / or the upper endwall portion. The rim portion not only enables one or more gripper elements to be attached to the storage container but also increases the structural rigidity of the storage container. Optionally, the rim portion is connected separately to the upper sidewall portion and / or the endwall portion.Thus, the metal container can be assembled in a modular manner, and the rim portion can be formed of a different material from the rest of the upper side wall portion and / or upper end wall portion, optionally providing greater weight reduction.

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

[0012] A single monolithic body of the donation portion provides a leak-proof tray to prevent juice from one or more items (usually food items) stored in a storage container from contaminating one or more items stored in an adjacent storage container in the stack.

[0013] To enable multiple storage containers to be stacked vertically on top of each other, the rim portion optionally includes a protruding lip that is turned inward and / or outward from the upper side wall portion and / or end wall portion to support the container bottom wall of an adjacent storage container located above in the stack. Thus, each storage container in a stack of multiple storage containers is stackable. Due to the protruding lip turned inward and / or outward, the container bottom wall of the vertically adjacent storage container can rest on the protruding lip without the contents of the storage container below being crushed, damaged, or soiled by the container bottom wall of the vertically adjacent storage container located above in the stack. Depending on whether the protruding lip protrudes inward or outward from the side wall and end wall 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 to be supported on the rim of the storage container.

[0014] The upper portion of the storage container is separate from the base portion, so that at least one of the mutually opposing upper side walls and / or end walls is separable, allowing at least a portion of the metal container body to be packed more easily. Separation of the mutually opposing upper side walls and / or end walls includes, but is not limited to, at least one edge or end of the mutually opposing upper side walls and end walls being physically separated from each other. This includes the mutually opposing upper side walls and / or end walls being physically separated from the container bottom wall. Due to the separable nature of the mutually opposing upper side walls and / or end walls, if either of the walls is damaged, the other portion of the storage container can be replaced. This not only reduces the cost of having to replace the entire storage container in the event of damage to any of the walls, but is also environmentally friendly as any portion of the storage container can be replaced with a spare part. Optionally, the upper side wall portion is separately fixed to the end wall portion.

[0015] Similarly, in order to allow one or more storage containers to be stacked on top of another storage container 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 located at diagonally opposite corners of the storage container that protrude into the opening of the storage container to support the bottom container wall of an adjacent storage container in the stack, and the plurality of stops are spaced above the container bottom wall to prevent one or more items in the storage container from being contaminated by the container bottom wall of an adjacent storage container above in the stack. For example, the storage container may include two or more stops at the diagonally opposite corners of the storage container. Two or more stops protrude inward into the opening of the storage container and are formed to support the bottom container wall of an adjacent storage container in the stack. Two or more stops may be spaced apart from the top of the container bottom wall and from the diagonally opposite corners of the metal container body to prevent an adjacent storage container located directly above the storage container from crushing or contaminating the contents of the storage container. Generally, the weight of a fully loaded storage container is up to 35 kg. 30 kg is the weight of the stock or goods, and 5 kg is the typical weight of the storage container. For a stack containing 20 fully loaded storage containers, the load that the storage containers of the stack must support will be 700 kg (6,867 Newtons). To increase support for adjacent storage containers in the stack, all four corners of the storage containers may include stops. The stops may be formed integrally with the metal container body, for example, indentations at the diagonally opposite corners of the storage containers.

[0016] In some embodiments of the storage and retrieval system, there may be a very large number of robotic load handling devices that run on a track system containing a large number of storage containers in a stack of grid framework structures. A significant number of storage containers used within the storage and retrieval system may obstruct 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 to prevent the contents of the storage containers from overheating due to and / or the contents of the storage containers. To mitigate this problem, optionally, at least one of the upwardly upright opposing sidewalls and / or end walls includes a plurality of ventilation openings. One or more ventilation openings in at least one of the upwardly upright opposing sidewalls and / or end walls allow cold air to circulate within the storage containers when the storage containers are maintained in the stack. For example, in a cooling zone where cooled air circulates around a stack of multiple storage containers, one or more ventilation holes located inside at least one of the upwardly facing sidewalls and / or end walls circulate the cool air inside the storage container to keep the contents of the storage container cold. Additionally, due to the high thermal conductivity of metal, heat can be easily transferred through the sidewalls and end walls of the storage container. This helps maintain the internal space within the storage container at the same temperature as the outside of the storage container. Therefore, because the thermal conductivity of the sidewalls and end walls of the storage container is relatively higher compared to storage containers made of insulating plastic materials, cooling from outside the stack of storage containers is rapidly transferred to the internal space of the storage container. However, the presence of one or more ventilation holes in the upwardly facing sidewalls and / or end walls is optional.The upward standing side walls and end walls of the solid chamber have an advantage in 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 represent a small proportion of the weight of the contents. Generally, in the industry, the weight of a storage container is about 5 kg. This is to prevent the lifting mechanism, including the lifting motor, from being burdened by the weight of the storage container and to allow larger weight contents to be stored in the container. Typically, the lifting motor is sized to lift a predetermined weight, and the lifting motor will attempt to lift the weight of the storage container exceeding that predetermined weight. To keep the weight of the storage container relatively low, at least a portion of the metal container body is optionally formed from a folded sheet metal blank, so that at least a portion of the metal container body is foldable in that it can be easily transported and also stood up for use. Due to the foldable nature of at least a portion of the metal container body, multiple storage containers can be packed and transported, for example, from a supplier or other storage and retrieval system and also stood up for use. In order to allow the storage container to be erected from a blank metal sheet, optionally, at least one of the upwardly standing side walls is pivotally connected to at least one of the upwardly standing end walls by a living hinge.

[0018] Alternatively, the sidewalls and endwalls may be assembled separately to form the walls of a storage container having a box-shaped structure with an open top or entrance. To assemble at least one of the sidewalls and endwalls separately, at least one of the upper sidewall portions is connected to at least one of the upper endwall portions. To permanently connect at least one of the upper sidewall portions to at least one of the upper endwall portions, optionally, at least one of the upper sidewall portions and / or at least one of the upper endwall portions includes at least one flange for permanently connecting at least one of the upper sidewall portions to at least one of the upper endwall portions. Each flange may be configured to overlap underneath and on top of an adjacent flange. At least one flange of the upper sidewall portions may be permanently connected to at least one flange of the upper endwall portions by the use of adhesive, welding, or riveting. In particular, the flanges of the upper sidewall portion and / or the upper endwall portion may be joined together by a mechanical clinching process. Alternatively, at least one upper sidewall portion may be releaseably connected to at least one upper endwall portion by a snap-fit ​​joint or an interlocking joint. For example, the snap-fit ​​joint may be based on a cantilever joint. Likewise, the interlocking joint may be a toggle latch.

[0019] Optionally, each corner of the metal container body includes a plurality of overlapping layers. These plurality of overlapping layers reinforce the corner of the metal container body to support a load from one or more storage containers placed above it when the storage container, particularly the metal container body, is placed in a storage container stack. Thus, there is rigidity through the corner of the metal storage container from the overlapping layers. Each corner may have two, three, or four overlapping layers.

[0020] Optionally, the storage container additionally includes guides at each corner of the storage container for aligning the grabber device of the load handling device. Using these guides, the grabber device can be easily aligned with openings or recesses in the rim portion of the metal container. The guides may be formed as elongated vertical recesses in the flanges of the upper sidewall portion and / or the endwall portion. To grasp the storage container, the grabber device uses guide pins located near or at each corner of the grabber device, and these guide pins are paired with corresponding openings or recesses formed at 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, in which case the sheet metal blank is drawn into the 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. Thus, the remainder of the metal container body is foldable as described above, making it easy to transport. At least one of the upwardly upright mutually opposing side walls comprises an upper side wall portion and a lower side wall portion, and / or at least one of the upwardly upright mutually 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, so that the upwardly upright mutually opposing side walls and end walls of the shallow portion of the metal container body form mutually opposing lower side wall portions and lower end wall portions of the metal container body. Optionally, at least one of the upper side wall portions is pivotally attached to each lower side wall portion of the metal container body, and / or at least one of the upper end wall portions is pivotally attached to each lower end wall portion of the metal container body. The mutually opposing sidewalls and endwalls of the deep-drawn metal blank form the lower sidewall portion and the lower endwall portion, respectively, of the metal container body. The height of the lower sidewall portion and the lower endwall portion, together with the height of the upper sidewall portion and the upper endwall portion, represents the total height of the mutually opposing sidewalls and endwalls of the metal container body. Thus, the sidewalls of the metal container may be a combination of the lower sidewall portion and the upper sidewall portion. Similarly, the endwalls of the metal container body may be a combination of the lower endwall portion and the upper endwall portion.

[0023] Optionally, at least one of the upper sidewall portions is removablely attached to each lower sidewall portion of the metal container body and / or at least one of the upper endwall portions is removablely attached to each lower endwall portion of the metal container body. For example, the walls of a deep-drawn sheet metal blank may be used to support the upwardly upright mutually opposing sidewalls and endwalls of the metal container body by accommodating the upwardly upright mutually opposing sidewalls and endwalls within the deep-drawn sheet metal blank.

[0024] To prevent either of the upwardly upright mutually opposing sidewalls and / or upwardly upright mutually opposing endwalls from collapsing due to the weight of one or more adjacent storage containers in the stack, the metal container body optionally comprises one or more wall reinforcements configured to support at least one of the upwardly upright mutually opposing sidewalls of the metal container body and / or at least one of the upwardly upright mutually opposing endwalls of the metal container body. For example, one or more sidewall reinforcements and / or endwall reinforcements may function as inserts to reinforce either of the upwardly upright mutually opposing sidewalls and / or upright mutually opposing endwalls, thereby improving the structural integrity of the storage container to withstand the weight of the stack of adjacent storage containers above it. To provide the necessary structural integrity to the upwardly upright mutually opposing sidewalls and / or upright mutually opposing endwalls of the storage container, preferably one or more sidewall reinforcements and / or endwall reinforcements are cast, for example, die-cast.

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

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

[0027] If one or more items stored in a storage container are food or groceries, it is important that the groceries be protected from contamination by the metal storage container. To prevent contamination of the groceries, the metal container body comprises an inner surface and an outer surface, and preferably, the inner surface comprises a polymer coating. The polymer coating protects the groceries stored in the storage container from inherent corrosion of the metal container body. The polymer coating or lining not only minimizes interaction between the metal container body and the groceries stored therein but also satisfies global food storage regulations. The polymer coating also provides a sealing coating on the inner surface of the storage container to prevent leakage from the storage container due to 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 mutual side walls and / or mutual end walls of a metal container body, preferably, at least a portion of the container bottom wall and / or mutual side walls and / or mutual end walls is reinforced by one or more ribs. Each of the one or more ribs may protrude outward and / or inward from the wall surface of the metal container body to reinforce the wall of the metal container body. One or more ribs may be incorporated into the bottom container wall and / or mutual side walls and / or end walls of the metal container body so that the bottom container wall and / or mutual side walls and / or end walls are corrugated. Alternatively, the upper side wall portion and / or upper end wall portion include ribs or beaks to minimize movement of the upper side wall portion and / or upper end wall portion. Preferably, the base portion includes one or more patterns embossed within the container bottom wall to increase the rigidity of the base portion.

[0029] The present invention may further provide a foldable stackable container that is stacked in a storage and retrieval system, the storage and retrieval system comprising a track system, the track system comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks that are transverse to the first set of parallel tracks in a substantially horizontal plane to form a grid pattern comprising a first set of parallel rails or tracks and a plurality of grid spaces or grid cells, the foldable stackable container comprising a metal container body, the container body comprising a container bottom wall, upwardly upright mutually opposing side walls and end walls, and a rim, the rim comprising a protruding lip that is turned inward and / or outward at the entrance of the storage container, so that one or more foldable stackable containers can be stacked on top of other containers, and at least a portion of the metal container body is formed from a monolithic blank of foldable sheet metal. For the purposes of the present invention, the foldable 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, for example, 0.55 mm, 0.6 mm, 0.7 mm, 0.8 mm, or 0.9 mm. When at least a portion of the metal container body is formed from a single blank of the foldable sheet metal, the metal container body of the storage container becomes easily transportable, as it does not appear as a large item for transport compared to conventional molded plastic storage containers in the art. Thus, a larger number of metal container bodies can be tightly packed and transported to an order fulfillment center that accommodates the storage and return system of the present invention, where the containers can be erected for use in the storage and return system.

[0030] To provide a foldable stackable container, 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 comprising a track system, the track system comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks transversely to the first set of parallel tracks in a substantially horizontal plane to form a grid pattern comprising a first set of parallel rails or tracks and a plurality of grid spaces or grid cells, the foldable stackable container comprises a metal container body, the container body comprising a container bottom wall, upwardly upright mutually opposing side walls and end walls, and a rim, the rim comprising a protruding lip that is turned inward and / or outward at the entrance of the storage container, so that one or more foldable stackable containers can be stacked on top of other containers, and at least a portion of the metal container body is cast. By casting, the walls (container bottom wall, mutually opposing side walls and / or end walls) are rigid, thereby providing a rigid metal container body that supports the weight of vertically adjacent storage containers in the stack. Optionally, the metal container body can be die-cast or investment-cast. The metal container body can be cast from aluminum or steel.

[0031] Preferably, the storage container may include a liner formed from food-grade material. The metal container body of the storage container is non-flammable, so any type of food-grade material may be used for the liner of the storage container. Therefore, the liner of the storage container is not limited to being non-flammable. Optionally, the liner includes food-grade plastic material and / or cellulose-based material. To ensure that the cellulose material has moisture resistance and / or oil resistance, the cellulose is optionally coated or impregnated with a wax material. 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. Since the liner includes paper or cardboard, the liner is optionally disposable. The liner may be a shallow base or tray to provide a cover for at least a portion of the inner surface of the box-shaped structure of the storage unit. Alternatively, the liner may extend across the entire inner surface of the box-shaped structure. To prevent food juices from leaking from the storage container and contaminating the food in the storage container located below in the stack, the liner is preferably a leak-proof container. Optionally, the leak-proof container is a one-piece thermoformed container produced, for example, by a blow molding or deep drawing molding process.

[0032] The present invention further provides a kit for assembling a storage container, wherein the kit is,

[0033] i) a base portion formed as a single monolithic body and having a container bottom wall, an upwardly standing base side wall portion and an end wall portion to form a tray; and

[0034] ii) Includes a separate upper portion including an upper side wall portion and an upper end wall portion.

[0035] Since the storage container includes separate upper and base portions, it can advantageously be supplied as a kit of parts and can also be assembled together, for example, by using a toggle latch, a snap-fit ​​joint, etc., and / or by spot welding the upper portion to the base portion. The storage container of the kit may include any of the features described above. The kit may further include two or more rim portions that can be separately connected to the upper sidewall portion and / or the end wall portion. Brief explanation of the drawing

[0036] Further features and aspects of the present invention will become apparent from the following detailed description of an exemplary embodiment with reference to the drawings. FIG. 1 illustrates an automated storage and retrieval system according to an exemplary embodiment of the present invention. Figure 2 is a schematic diagram of a stack of boxes placed within the framework structure of Figure 1, viewed from above. FIG. 3 is a schematic diagram of a system of a known load handling device operating on a grid framework structure. FIG. 4 is a schematic perspective view of a load handling device showing a container receiving space within the main body of the load handling device. FIGS. 5a and 5b are schematic cutaway perspective views of the load handling device of FIG. 4, where (a) shows a container that accommodates the container accommodation space of the load handling device, and (b) shows the container accommodation space of the load handling device. FIG. 6 is a schematic perspective view of a grabber device located on top of a storage container. FIG. 7a is a schematic perspective view of a grabber device mounted on a storage container. FIG. 7b is a schematic perspective view of a grabber device combined with a storage container. FIG. 8 is a schematic perspective view of a storage container formed by a deep drawing process according to a first embodiment of the present invention. FIG. 9 is a schematic perspective view of a storage container formed by a deep drawing process according to a second embodiment of the present invention. FIG. 10 is a schematic perspective view of a storage container formed by a deep drawing process, (a) is an exploded view of the assembly components of the storage container, and (b) shows an assembled storage container according to a third embodiment of the present invention. FIG. 11 is a schematic perspective view of a storage container partially formed by a deep drawing process, (a) is an exploded view of the assembly components of the storage container, and (b) shows an assembled storage container according to a fourth embodiment of the present invention. FIG. 12 is a schematic perspective view of a storage container partially formed by a deep drawing process according to a fifth embodiment of the present invention. FIG. 13 is a schematic perspective view of a storage container partially formed by a deep drawing process, (a) is a view of the storage container before assembly, and (b) shows the assembled storage container according to the 6th embodiment of the present invention. FIG. 14 is a schematic perspective view of a storage container partially formed by a deep drawing process, (a) is a view of the storage container before assembly, and (b) shows the assembled storage container according to the seventh embodiment of the present invention. FIG. 14c is a schematic perspective view of an assembled storage container showing the connection of the upper wall portion by a releaseable toggle latch. FIG. 14d is a perspective view of a releaseable toggle latch for connecting the upper wall portions of the metal container body shown in FIG. 14c together. FIG. 14e is a perspective view of individual parts of the metal container body shown in FIG. 14b and FIG. 14b in a laminate. FIG. 15 is a schematic perspective view of a storage container partially formed by a deep drawing process, (a) is a view of the storage container before assembly, and (b) shows the assembled storage container according to the eighth embodiment of the present invention. FIGS. 15c and 15d are schematic perspective views of the upper side wall and upper end wall of a storage container according to the eighth embodiment of the present invention. FIG. 15e is a schematic perspective view of a corner of the upper part of a storage container according to the eighth embodiment of the present invention. FIG. 16 is a schematic perspective view of a storage container partially formed by a deep drawing process, representing a ninth embodiment of the present invention. FIG. 17 is a schematic perspective view of a storage container partially formed by a deep drawing process, wherein (a) shows an assembly view of a storage container according to the 10th embodiment of the present invention, (b) shows an assembly view of a storage container according to the 10th embodiment of the present invention, (c) shows a rim portion of a storage container according to the 10th embodiment of the present invention, (d) shows a schematic perspective view of a corner of an upper portion of a storage container according to the 10th embodiment of the present invention, and (e) shows a schematic perspective view of an interface between an upper portion and a base portion of a storage container according to the 10th embodiment of the present invention. FIG. 18 is a schematic perspective view of a storage container similar to FIG. 17, which is partially formed by a deep drawing process, showing an assembly drawing of a storage container according to the 11th embodiment of the present invention. FIG. 19 is a schematic perspective view of a storage container partially formed by a deep drawing process, (a) showing the assembled view of the storage container, and (b) showing the assembled storage container according to the 12th embodiment of the present invention. FIG. 20 is a schematic perspective view of a storage container partially formed by a deep drawing process, (a) showing the assembled view of the storage container, and (b) showing the assembled storage container according to the 13th embodiment of the present invention. FIG. 21 is a schematic diagram of a stack of storage containers before assembly of FIG. 19 or FIG. 20. FIG. 22 is a schematic perspective view of (a) a blank of a foldable metal sheet and (b) a metal container body erected from the blank according to the 14th embodiment of the present invention. FIG. 23 is a schematic perspective view of (a) a monolithic blank of a foldable metal sheet and (b) a metal container body erected from the monolithic blank according to the 15th embodiment of the present invention. FIG. 24 is a schematic perspective view of a cast storage container according to the 16th embodiment of the present invention. FIG. 25 is a schematic perspective view of a storage container including a hollow wall according to the 17th embodiment of the present invention. FIG. 26 is a schematic diagram of a storage container comprising a non-combustible enclosure and a fire-resistant body forming a partial liner. FIG. 27 is a schematic diagram of a partial liner of the fire-resistant body shown in FIG. 26. FIG. 28 is a schematic diagram of a storage container comprising a non-combustible enclosure and a fire-resistant body forming a full-height liner. FIG. 29 is a schematic diagram of the full height liner of the fire-resistant body shown in FIG. 28. Specific details for implementing the invention

[0037] As shown in FIGS. 1 and 2, storage containers (10) (also known as boxes or totes) are stacked vertically on top of each other to form a stack (12). This stack (12) is placed inside a grid framework structure (14) in a warehouse or manufacturing environment. The grid framework structure consists of a plurality of storage columns or grid columns. Each grid within the grid framework structure has at least one grid column for storing the stack of containers. FIG. 1 is a schematic perspective view of the grid framework structure (14), and FIG. 2 is a top-down view of a single stack (12) of containers (10) placed inside the framework structure (14). Each container or box (10) generally holds a plurality of products (not shown), and the products inside the container (10) may be the same or different types of products depending on the use. Each container (10) may be used, for example, to store groceries (i.e., food items). Additionally, the box (10) may be physically divided to accommodate a plurality of different stock items.

[0038] In the description below, the box (10) is used to denote a storage container for storing inventory items, and the delivery container (DT) is used to denote a container that has been filled or is scheduled to be filled to fulfill a customer order given by a customer. It will be understood that these terms are used in this document for convenience of reference and description. However, it should be noted that the box (10) and the container (DT) may have the same shape and configuration. Additionally, the delivery container (DT) may be stored in the box (10) within the storage system or a part thereof.

[0039] The grid framework structure (14) includes a plurality of upright members or upright columns (16) that support horizontal members (18, 20). A first set of parallel horizontal grid members (18) are arranged perpendicularly to a second set of parallel horizontal grid members (20) to form a plurality of horizontal grid structures supported by the upright members (16). The members (16, 18, 20) are generally made of metal and are generally welded together, bolted together, or a combination of both. A container (10) is stacked between the members (16, 18, 20) of the grid framework structure (14), so that the grid framework structure (14) inhibits horizontal movement of the stack (12) of the container (10) and guides vertical movement of the container (10).

[0040] The top level of the grid framework structure (14) includes rails (22) arranged in a grid pattern across the top of the laminate (12). Referring further to FIG. 3, the rails (22) guide a plurality of load handling devices (30). A parallel rail (22) of a first set (22a) guides the movement of a robotic load handling device (30) in a first direction (e.g., X-direction) across the top of the grid framework structure (14), and a parallel rail (22) of a second set (22b) arranged perpendicular to the first set (22a) guides the movement of a load handling device (30) in a second direction (e.g., Y-direction) perpendicular to the first direction. In this way, the robotic load handling device (30) can move two-dimensionally sideways in the horizontal XY plane by means of the rail (22), so that the load handling device (30) can be moved to a position above any stack (12).

[0041] Each load handling device (30) includes a vehicle (32) positioned to move in the X and Y directions on a track or rail (22) of a grid frame structure (14) above a stack (12) (see FIG. 4). FIG. 4 and FIG. 5 illustrate a load handling device (30) according to one embodiment of the present invention as described in PCT Patent Publication No. WO2015 / 019055 (Ocado Innovation Limited) and International Patent Application WO 2015 / 140216 (Ocado Innovation Limited), the contents of which are incorporated herein by reference. The load handling device (30) includes a vehicle body (32), and the vehicle body is equipped with a lifting mechanism (33) (see FIG. 4) including a winch or crane mechanism (35) for lifting a storage container or box (10) (also known as a tote) from above. The crane mechanism (35) includes a winch cable (38) wound onto a spool or reel and a grabber device (39). Typically, the lifting device includes a set of lifting tethers (38) that extend vertically and are connected to or near the four corners of the grabber device (39) to be releasedly connected to the storage container (10) (one tether is located near each of the four corners of the grabber device). The grabber device (39) is configured to grasp the top of the storage container (10) and also to lift the storage container from a stack of containers in a storage system of the type shown in FIGS. 1 and 2. Typically, the grabber device (39) is composed of a lifting frame. Further details of the grabber device are discussed below.

[0042] The vehicle body (32) includes an upper portion and a lower portion (see (a and b) in FIG. 5). The lower portion is equipped with two sets of wheels (34, 36) that run on rails located at the top of the framework structure of the storage system. The upper portion of the vehicle body (32) can accommodate most of the bulky components of the load handling device. Generally, the upper portion of the vehicle body accommodates a drive mechanism for driving both the wheels and the lifting mechanism, along with an on-board rechargeable power source for providing power to the drive mechanism and the lifting mechanism.

[0043] The lower portion of the vehicle body (32) includes a wheel assembly driven to enable the vehicle to move along the rails in the X and Y directions, 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 with two adjacent rails of the first set (22a) of the rail (22). Similarly, a second set of wheels (36), consisting of a pair of wheels (36) at each side of the vehicle (32), is positioned to engage with two adjacent rails of the second set (22b) of the rail (22). One or both sets of wheels move vertically so that each set of wheels is lifted off its respective rail, thereby allowing the vehicle to move in the desired direction. When the first set of wheels (34) is combined with the first set of tracks or rails (22a) and the second set of wheels (36) is lifted off the track or rail (22), the wheels (34) move the load handling device (30) in the X direction through a drive mechanism (not shown) built into the vehicle (32). To move the load handling device (30) in the Y direction, the first set of wheels (34) is lifted off the track or rail (22), and the second set of wheels (36) is lowered and combined with the second set of tracks or rails (22a). Then, the drive mechanism is 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 so that each set of wheels can be lifted off the respective rails, thus allowing the vehicle to move in the desired direction on the track system.

[0044] Wheels are positioned around the periphery of a cavity or recess (known as the container receiving recess (40)) located in the lower part. As shown in FIGS. 5a and 5b, the recess (40) is sized to accommodate the storage container or box when the storage container or box is lifted by a crane mechanism. When in the recess, the container is lifted away from the rail below, so that the load handling device can move to a different location. When a target location is reached, such as another stack, an access point within the storage system, or a conveyor belt, the box or storage container can be lowered from the container receiving space and released from the grabber device (39). In this way, as shown in FIG. 3, one or more robotic load handling devices (30) can move around the top surface of the track (12) of the stack (12) in 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 (38) for lifting one or more boxes (10) from a stack (12) to access required items stored inside the boxes.

[0045] The body of the vehicle (32) may include a container receiving space in the form of a cavity (40) for receiving a box (10) (see FIG. 5). This cavity (40) is sized to hold a box or storage container (10). The lifting mechanism includes a set of lifting tethers (38) that extend vertically and are connected to the four corners of a lifting frame (not shown) (otherwise known as a grabber device) for a releaseable connection to the storage container (one tether is located near each of the four corners of the grabber device). The grabber device is configured to grasp the top of the storage container and lift the storage container from a stack of containers in a storage system of the type shown in FIG. 1 and 3. The lifting mechanism lifts the box (10) from the stack (12) into the cavity (40) within the body of the vehicle (32). When a box (10) is lifted by a winch means, a container receiving space (40) for receiving the box is placed inside the vehicle body (32) shown in FIG. 4, but the present invention is not limited to the container receiving space (40) being located inside the vehicle body (32). The present invention is also applicable when the container receiving space is located under the cantilever, such as when the vehicle body of the load handling device has a cantilever structure as described in WO2019 / 238702 (Autostore Technology AS). For the purposes of the present invention, the term “vehicle body” is interpreted as selectively covering the cantilever so that the grabber device is located under the cantilever. However, for ease of explanation of the present invention, the container receiving space for receiving the container is placed within a cavity or a recess inside the vehicle body. The container receiving space allows a number of products to be accessed at any time from a number of locations within the grid and stack.

[0046] A robotic load handling device (30) removes a box (10) containing stock items (not shown) and transports the box (10) to a pick station (not shown), where the required stock items (28) are removed from the box (10) and placed into the box (10) containing a delivery container (DT). It is important to note that the delivery container (DT) may be placed inside the box (10). The box (10) may contain stock items or the delivery container (DT). Additionally, the delivery container (DT) may contain at least one bag, and the stock items are picked directly into the bag at the pick station (not shown).

[0047] An empty box (10) or a box containing a delivery container (DT) or a box containing a delivery container (DT) and a bag can all be stored within a stack (12). It will be understood that all boxes (10) have substantially the same external shape and configuration.

[0048] FIG. 3 illustrates a typical storage and retrieval system as described above, which has a plurality of load handling devices (30) operating on a grid above a stack (12). FIG. 1 and 3 illustrate a box (10) in a stack (12) within a storage system. It will be understood that any given storage system may have a large number of storage containers or boxes (10), and many different items may be stored in the boxes (10) of the stack (12), and each box (10) may contain different categories of inventory items within a single stack (12).

[0049] In one storage and retrieval system further described above in British patent application No. GB1410441.8 (Ocado Innovation Limited), incorporated by reference to this specification, the storage and retrieval system may further include a series of boxes (10) containing a delivery container (DT) containing a customer's order or may further include boxes (10) containing stock items waiting to be picked. These different boxes (10) and combinations thereof may be included in the storage system and may be accessed by a robotic load handling device (30) as described above.

[0050] FIG. 6 illustrates a grabber device positioned on a box (10) of a form intended for use within the storage and retrieval systems of FIG. 1 through 3. The storage container or box (10) is substantially box-shaped, comprising an open top (43), a container bottom wall (44), and mutually opposing side walls (46) (a and b) and end walls (48) (a and b). In a specific example shown in FIG. 6, the box (10) has a substantially rectangular container bottom wall (44) such that the length of the mutually opposing side walls (46) (a and b) is longer than the length of the mutually opposing end walls (48) (a and b). The mutually opposing side walls (46) (a and b) and end walls (48) (a and b) of the box include one or more ribs to reinforce the side walls and end walls of the storage container. Multiple boxes (10) may be stacked in a self-supporting stack (12), and multiple stacks (12) are placed within a grid framework structure (14) as described above. It will be understood that a storage facility of the type described with reference to FIGS. 1 through 3 may contain a large number of boxes (10), in some cases hundreds of thousands. Generally, each box (10) must be able to withstand the load of multiple boxes (10) in the stack. The load of the box stack is supported by the maximum load of 20 fully loaded boxes. The weight of a fully loaded box is about 35 kg, of which 5 kg is the weight of the box alone. For example, a stack of 20 boxes (10) will exhibit a load of 700 kg or 6,867 N. One or more ribs on mutually opposing side walls and end walls reinforce the side walls and end walls to prevent the side walls and end walls in the stack from buckling under such load.

[0051] To allow air to flow within the box (10) when the box is maintained in a stack, the side walls (46) (a and b) and / or end walls (48) (a and b) of the box (10) include one or more slots or openings or ventilation holes (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 within and around the storage and retrieval system to flow within the box (10). This is particularly important when the box (10) is located in a cooling zone of a storage and retrieval system where cold air from a refrigeration or air conditioning unit circulates around at least a portion of the grid framework structure to keep items such as food at a low temperature. In a cooling system such as that described in International Patent Publication No. WO2016 / 193419 (Ocado Innovation Limited), air needs to flow within the storage system and through the boxes (10) and the stack (12) of the boxes (10). The system described in this international patent application is incorporated by reference and discloses a storage system comprising one or more heaters and / or one or more coolers for generating a 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 a portion of the storage and retrieval system needs to be cooled to a lower temperature to store items requiring cooling, such as fruits and vegetables, it is more important that the airflow passing through the system cools the items to be stored. Although embodiments of this specification are described in relation to cooling the storage system, it will be understood that items stored in the storage system can be heated in a similar manner using the same method described. Furthermore, although the above description refers to airflow, it will be understood that any suitable gas may be circulated to heat or cool the system as needed.

[0052] In addition to allowing air to circulate within the box, the slots (50) of the box (10) allow the same amount of storage volume to be utilized while reducing the weight of the container (10) and maintaining the structural integrity of the box (10). Advantageously, providing holes (50) in the container (DT) or box (10) also reduces the cost of each container (DT) or box. In a storage and retrieval system (1) containing hundreds of thousands of containers and boxes, this can represent significant savings. In the drawing of the box (10) shown in FIG. 6, two sides of the container or box include openings or holes (50). One or more handles (52) are integrally formed on the end walls (48) (a and b) of the box (10) so that the storage container can be manually picked up by an operator. Openings or ventilation holes (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 the leakage of fluid that accidentally escapes from the contents of the storage container and contaminates the contents of adjacent storage containers within the stack.

[0053] Also shown in FIG. 6 is a grabber device (39) positioned on the top of the box (10) (forming part of the lifting mechanism (33) of the robotic load handling device). The lifting mechanism (33) used to lift the container into the container receiving space can take any suitable form and includes a winch or crane mechanism (see FIG. 4). The crane mechanism includes a winch cable (38) wound on a spool or reel and a grabber device (39). The grabber device (39) is configured to grasp the top of the container (10) and lift the container from a stack of containers in a storage system of the type shown in FIG. 1 and 2. Generally, the grabber device (39) is composed of a frame (54) and four lifting tethers (38) are fixed to each corner of the grabber device (39) (see FIG. 5b). For maximum stability and load capacity, generally four lifting tethers (38) are used to wind up the grabber device (39) with a winch, and one tether is placed near each corner of the grabber device (39) or at each corner, but other arrangements using fewer tethers, for example, may be used if desired. One end of each tether, e.g., the first end, is wound onto a spool of a load handling device, and the other end, e.g., the second end, is secured to the grabber device (39) generally at each corner of the grabber device by a suitable bracket (not shown). The number of tethers attached to the grabber device depends on the ability to keep the grabber device horizontal during operation when lifting the container (10), and the ability to withstand the tension applied to the tethers when lifting the container (which may have a weight of up to 40 kg) without extending or stretching under a predetermined applied tensile stress (i.e., cannot be extended).To possess the necessary physical properties (Young's modulus), tethers are generally in the form of tape, but other tethers having the physical properties required to wind up containers with a winch are also permitted for winding boxes from a laminate with a winch.

[0054] In a specific embodiment shown in FIG. 6, the frame (54) of the grabber device has four corner portions (56), a normal side and a bottom side. To grasp the container (10), the grabber device (39) includes four positioning pins or guide pins (58) near or at each corner of the grabber device (39), which are paired with corresponding cutouts or holes (60) formed at the four corners of the container (10). The grabber device also includes four gripper elements (62) (see FIG. 7a) positioned on the bottom side of the grabber device (39) and coupled with the edge (64) of the box (10). The positioning pins (50) help to properly align the gripper elements (62) with the corresponding holes (60) in the edge of the container. In a specific embodiment shown in FIG. 7a, each gripper element (62) includes a pair of wing portions (66) that are foldable to be accommodated in a corresponding hole (60) in the rim (64) of the container, and have an open-extended configuration having a size larger than the hole (62) in the rim (64) of the container (10) in at least one dimension so as to be locked onto the container (10) (see FIG. 7b). The wing portions are driven into the open configuration by a drive gear (not shown). More specifically, at least one head of the wing portions includes a plurality of teeth that engage with the drive gear, so that when the gripper element (62) is actuated, the pair of wing portions are rotated from the foldable configuration (Fig. 7a) to the open-extended configuration (7b) by the rotation of the drive gear.

[0055] When in a folded or closed configuration, the gripper element (62) is sized to be accommodated in a corresponding hole (60) in the rim (64) of the container (10) as shown in FIG. 7a. Each foot of a pair of wing portions includes a stop portion (68) (see FIG. 6), such as a boss, so that when accommodated in the corresponding hole (60) in the rim (64) of the container (10), the stop portion (68) is joined to the bottom surface of the rim (64) when in an expanded open configuration so as to be locked onto the container when the grabber device (39) is winched upward toward the container receiving space of the load handling device. FIG. 7b shows the configuration of the gripper element in an expanded configuration for lifting the box (10) into the container receiving space of the robotic load handling device.

[0056] The gripper element (64) is received in a hole (60) in the rim (64) of the container (10) when the 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 bottom surface of the grabber device. At this depth, the gripper element (64) is actuated to grasp the container (10) in response to a signal from one or more depth sensors (not shown) mounted on the bottom surface of the grabber device (39).

[0057] Typically, the box (10) is composed primarily of thermoplastic material and is injection molded or blow-molded. Known thermoplastic materials commonly used for molding storage containers include polyolefins, such as polypropylene or polyethylene (e.g., high-density polyethylene (HDPE)), acrylonitrile butadiene styrene (ABS), and polycarbonates including copolymers thereof. However, the problem with these plastic materials is that they are flammable and emit toxic fumes. Once a fire starts within the storage and retrieval system, the flammability and heat-generating properties of the box (10) material can cause the fire to spread throughout the storage and retrieval system, posing a risk to life. Not only is the container (10) flammable, but the combustion fumes emitted from the burning thermoplastic material are highly toxic, including benzene, which is known to be a carcinogen. Inhaling fine particles from the burning debris can cause respiratory irritation. Consequently, extreme fire prevention methods and systems, such as sprinklers and smoke / heat detection units, are integrated 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 (the fire in the box (10) plays a major role in the spread of fire), the problem of fire spreading throughout the storage and retrieval system still remains.

[0058] The present invention alleviates the above problem by providing a storage container comprising a metal container body including a container bottom wall, mutually opposing side walls, and mutually opposing end walls. In the examples of various types of storage containers discussed below with reference to FIGS. 8 through 25, the entire storage container is formed as a metal container body in that the metal container body is a storage container. However, the storage container of the present invention is not limited to being formed entirely as a metal container body, and at least a portion of the storage container may include other materials, e.g., plastic materials. For example, the metal container body may form the metal lining of the storage container. A storage container comprising a metal container body is also applicable to a delivery container (DT) in that the delivery container may also include the metal container body of the present invention, which includes a container bottom wall, mutually opposing side walls, and mutually opposing end walls.

[0059] The storage container described below with reference to FIGS. 8 through 25 relates to a storage container formed from a metal container body. For ease of explanation, the metal container body may be referred to as a storage container in the following examples. The metal container body of the present invention may have a shape similar to existing storage containers for storing articles in a grid framework structure, for example, having a substantially rectangular container bottom wall and mutually opposing side walls and end walls. The metal storage container may be used between the traditional plastic storage containers of the storage and retrieval system described above with reference to FIG. 3. The flame-resistant behavior of the metal storage container may be used to form a flame-resistant barrier in the grid framework structure. For example, a plurality of stacks of metal storage containers may be arranged to form one or more flame-resistant barriers surrounding a plurality of stacks of plastic storage containers. One or more flame-resistant barriers comprising metal storage containers may be used to contain flames within the grid framework structure.

[0060] There are many ways to manufacture a storage container comprising a metal container body according to the present invention. For use in an automated storage and retrieval system, the main feature of the storage container is its lightweight nature, with a weight of less than 8 kg, preferably less than 6 kg, and more preferably less than 5 kg. The storage container comprising a metal container body must also have sufficient structural rigidity to withstand the load applied when placed in a stack. A grid framework structure can support a stack of storage containers up to the height of 20 storage containers. Considering that the weight of each storage container is up to 35 kg, this amounts to a total weight of 700 kg. Different examples of storage containers comprising a metal container body according to the present invention are shown below. When a storage container comprising a metal container body is used for storing food products, it is important that the storage container is leak-proof to prevent food from leaking out of the container and contaminating other food products stored in adjacent storage containers within the stack. Since fluids tend to sink to the base of the storage container, the base of the metal container body is made leak-proof, and vent holes in the side walls and / or end walls of the metal container body are positioned at a predetermined height above the bottom of the container to prevent fluids from escaping through the vent holes.

[0061] FIG. 8 is an example of a storage container (110) comprising a metal container body (112) according to a first embodiment of the present invention, wherein the storage container (110) is formed by a deep drawing press workpiece of a sheet metal blank comprising a container bottom wall (115), mutually opposing side walls (116) (a and b) and mutually opposing end walls (118) (a and b). The sheet metal blank is mechanically drawn into a forming die similar to the shape of the storage container by the mechanical action of a punch. The advantage of the deep drawing process over other metal forming processes is that it can produce a leak-proof storage container. The storage container (110) may be manufactured from stainless steel sheet metal having a thickness in the range of 0.5 mm to 2.0 mm, for example, the thickness may be 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, may be used to manufacture the metal container body. To provide the necessary structural rigidity of the storage container walls, the thickness of the sheet metal blank is preferably about 2 mm. The storage container (110) shown in FIG. 8 is an example in which the storage container is formed by a full deep drawing process using a single or monolithic sheet metal blank. Similar to the storage container described above, the mutually opposing side walls (116) (a and b) and end walls (118) (a and b) of the storage container (110) include one or more slots or openings or ventilation holes (120) that allow air flow within the storage container. One or more slots (120) may be cut and formed in the sheet metal blank before the deep drawing process, or alternatively, one or more slots may be cut and formed or stamped in the mutually opposing side walls and / or end walls of the storage container after the deep drawing process.Similarly, to reinforce the walls of the storage container and improve the structural integrity or rigidity of the formed storage container, one or more ribs (122) may be stamped on the side walls (116) (a and b) and end walls (118) (a and b) of the storage container (110). Similar to storage containers in the art, one or more handles (124) are formed on the side walls and / or end walls of the storage container. A lip or flange (126) is formed on at least a portion of the edge to allow the grabber device of the lifting mechanism to engage with the edge of the storage container to lift the storage container into the container receiving space of the robotic load handling device. To create the lip or flange (126), the upper edges of the mutually opposing side walls and / or mutually opposing end walls are turned inward and / or outward or bent. In a particular example of the first embodiment of the present invention, the rim at the upper edge of the mutually opposing end walls of the metal container body is turned outward to form a flange or lip (126) for a grabber device, in particular a gripper element, to be coupled with the rim of the storage container. This lip or flange (126) may have one or more openings (not shown) into which the gripper element is received.

[0062] To enable storage containers of the first embodiment of the present invention to be stacked vertically on top of each other in a storage and retrieval system, the storage containers include one or more stop portions (128) at the corners of the storage containers (110). The container bottom wall of an adjacent storage container located above in the stack is butted against or supported by one or more stop portions of the storage container located below, thereby preventing the container bottom wall of the adjacent storage container from contaminating or crushing the contents of the storage container located below in the stack. In a specific embodiment of the present invention shown in FIG. 8, the stop portion (128) is formed as one or more indentations extending inward from the corner into the internal space of the metal container body (112).

[0063] To provide additional structural support to the deep drawing storage container of the first embodiment of the invention shown in FIG. 8 to support the load when placed in a stack, one or more corner posts (230) may be mounted on the corners of the storage container (220) from the outside or inside. In the exemplary second embodiment of the invention shown in FIG. 9, corner posts (230) are mounted on each corner of the storage container (220) from the outside. Each corner post (230) at the corner of the storage container extends along the entire height or depth of the storage container (220), so that the corner posts (230) support the entire weight of the adjacent storage container above in the stack, and the metal container body (212) simply provides the function of sealing the contents inside the storage container. In other words, the corner posts (230) provide a seating surface for the adjacent storage container in the stack. To provide the necessary structural rigidity, the corner posts are cast from metal, preferably die-cast. Considering that the thickness of the corner posts is greater than the walls of the metal container body made of sheet metal blanks, other lightweight materials, such as plastic materials, may be used in the production of the corner posts. Consequently, the materials of the storage container may be a combination of metal forming the metal container body and plastic corner posts at the corners of the metal container body. Using plastic corner posts helps to keep the total weight of the storage container low, for example, less than 6 kg, preferably less than 5 kg.

[0064] In the exemplary third embodiment of the invention shown in FIG. 10 (a and b), one or more of the mutually opposing side walls (316) (a and b) and / or mutually opposing end walls (318) (a and b) of the deep-drawn metal container body (312) of the storage container (310) may be reinforced by one or more inserts or wall reinforcements (332). As shown in FIG. 10, the wall insert (332) is positioned in contact with each of the mutually opposing end walls (316) (a and b) of the metal container body (312) and extends from the container bottom wall (315) to the rim (334) at the upper edge of the metal container body (312). To provide a supporting surface that facilitates stacking adjacent storage containers in a stack, the upper edge of the wall insert (332) is turned outward to form a rib (326) at the rim of the metal container body. The outwardly turned lip (326) includes one or more openings (336) to allow the grabber device to engage with the rim of the metal container body and lift the storage container from its stack. The wall reinforcement or insert (332) may be cast in plate, preferably die-cast, to provide the structural integrity necessary to support the weight of adjacent storage containers in the stack to the wall of the storage container (310). Metal, e.g., steel or aluminum, is preferably used to cast the wall reinforcement (332), but other structural integral materials such as plastic may also be used to manufacture the wall reinforcement. The wall reinforcement (332) may optionally include one or more recesses (338) located near the edge or entrance of the storage container (310) to facilitate stacking of the storage container, that is, 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 located above in the stack.The lower edge of the wall reinforcement (332) may include one or more tabs (340) that are abutted against the container bottom wall (315) of the metal container body (312) or received in a slot of the bottom container wall (315). The walls of the metal container body (312), namely the mutually opposing side walls (316) (a and b) and the mutually opposing end walls (318) (a and b), are inclined outward from the container bottom wall (315), so that the metal container body (312) is tapered. The tapered body allows the metal container body to be fitted inside another metal container body, so that multiple storage containers can be neatly stacked inside each other and thus occupy a smaller storage space. When in use, wall reinforcements (332) may be inserted into 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) so that one or more storage containers can be supported on top of each other. During transport, wall reinforcements (332) may be stored separately so that multiple metal container bodies (312) can be neatly stacked together.

[0065] The metal container body of the first, second, and third embodiments of the present invention is formed from a full 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 fattled or cut to a certain size to form the metal container body. Examples of fattling include, but are not limited to, cutting and / or filing the edges of the deep-drawn structure. The full deep-drawing process has the problem that the product is bulky because the storage container occupies a relatively large portion of the storage space during transport. Considering that a typical storage system requires thousands of storage containers, 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 reveal bulky products during transport or when stored for use. Compared to forming the metal body of a storage container by a full deep drawing process as discussed with reference to FIGS. 8 through 10 (a and b), the metal container body as shown in FIGS. 11 (a and b) through 16 may be produced by a two-stage forming process combining the erection of one or more blanks including foldable side walls and a deep drawing process. In the exemplary embodiments shown in FIGS. 11 (a and b) through 20, the metal container body comprises a lower portion (otherwise known as a base portion) and an upper portion. The terms lower portion and base portion are used interchangeably in this patent application. The lower portion comprises a deep drawing base comprising a container bottom wall forming a shallow base or tray and mutually opposing side walls and end walls. By the deep drawing process for forming the lower portion, the base portion of the metal container body may be made leak-proof.The upper portion of the metal container body is foldable in such a way that the upper portion can be erected from a folded sheet metal blank or cast into a plate that is pivotally connected together. The sheet metal blank (948) may include one or more folding lines to assist in the folding of the sheet metal blank to define the side walls and end walls of the metal container body. The advantage of forming the metal container body in a two-stage forming process is that the storage of the metal container body, including the upper and lower portions, for transport allows for efficient use of storage space. For example, multiple bases can be stacked together for transport. Similarly, multiple sheet metal blanks or plates can be flattened and then erected at the point of use.

[0066] FIGS. 11(a and b) is an exemplary embodiment of a metal container body (412) formed by a two-step forming process according to a fourth embodiment of the present invention. FIG. 11a shows a metal container (410) formed by two parts, namely a lower part (444) and an upper part (442), and FIG. 11b shows that separate parts (444, 442) come together to form a box-shaped structure of a metal container body (412) according to an exemplary embodiment of the present invention, namely, the lower part (444) forms the base part of the metal container body and the upper part (442) forms the upper part 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) comprising the container bottom wall (415), upwardly upright mutually opposing base side walls (446) (a and b), and end walls (448) (a and b). The upper portion (442) is formed by two separate sheet metal blanks (450) (a and b) that are folded to form mutually 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 folded to form one upper end wall (454a) of the metal container body and a portion of a pair of mutually opposing upper side walls of the metal container body. The second sheet metal blank (450b) is folded to form a portion of the other upper end wall (454b) of the metal container body and a pair of mutually opposing upper side walls of the metal body. The mutually opposing upper side wall portions are pivotally attached to the respective upper end walls (454) (a and b) of the first and second sheet metal blanks (450) (a and b) by means of a living hinge (460) or other suitable pivotable connection. The first and second sheet metal blanks (450) (a and b) include one or more folding lines that assist in the folding of each sheet metal blank to form the upper side walls and end walls of the metal container body.Consequently, the first and second sheet metal blanks are folded to form two separate C-shaped folds, so that when erected, assembled, or gathered together as shown in FIG. 11b, the mutually opposing upper sidewall portions from each of the first sheet metal blank (450a) and the second sheet metal blank (450b) lie in substantially parallel vertical planes. In other words, the C-shaped folds are gathered together to form a tubular structure that forms the upper portion of the metal container body. This tubular structure is provided in the lower or base portion (444), which is inserted into the shallow base of the lower portion (444) of the metal container body (412) to form a box-shaped structure having an open end or entrance portion as shown in FIG. 11b. When assembled together, the mutually opposing sidewalls (416) (a and b) of the metal container body (412) include an upper sidewall portion and a lower sidewall portion. Similarly, the mutually opposing end walls (418) (a and b) of the metal container body (412) include an upper end wall portion and a lower end wall portion. The mutually opposing side walls (446) (a and b) and end walls (448) (a and b) of the shallow portion of the metal container body each form a lower side wall portion and a lower end wall portion of the metal container body. The mutually opposing side walls and end walls of the upper portion of the metal container body (412) form an upper side wall portion and an upper end wall portion of the metal body. At least a portion of the metal container body can be folded for ease of transport by a combination of a deep-drawn shallow base and a C-shaped fold. The foldable portion of the metal container body comprising a sheet metal blank may also include a plurality of ventilation holes (462) stamped into the sheet metal blank to assist in the circulation of a fluid (e.g., air) within the internal space of the metal container body. The thickness of the sheet metal blank for forming the lower part and / or the upper part is 0.It may be 5 mm to 1 mm thick and may be made of stainless steel, but other metals such as aluminum may also be used in the manufacture of the metal container body. The mutually opposing side walls and end walls of the lower portion may be sloped 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 a number of shallow bases or trays (444) to be conveniently stacked together as shown in FIG. 21.

[0067] Additionally, in FIG. 11 (a and b), one or more stop portions (464) are shown at the corners of the metal container body (412), which are spaced apart from each other and configured to allow vertically adjacent storage containers to be stacked vertically on top of each other. The stop portions (464) at the corners are spaced apart from the top of the container bottom wall (415) to prevent the container bottom wall of the adjacent storage container on top of the stack from pressing down on the contents of the storage container on the bottom. In a specific embodiment shown in FIG. 11 (a and b), one or more stop portions (464) are formed by stamping a recess at the corners of the metal container body, but other means of forming stop portions may be applied to the present invention. At least one normal edge of the mutually opposing walls at the perimeter of the metal container body is directed outward to form a lip (466) for the grabber device of the load handling device to be releasedly coupled with the storage container including the metal container body to pick from the stack.

[0068] As shown in FIG. 11 (a and b), instead of the upper part of the metal container body being supported by the shallow base of the lower part by inserting the C-shaped fold into the shallow base, in the exemplary fifth embodiment of the invention shown in FIG. 12, the upper side wall portion (570) (a and b) and the end wall portion (572) (a and b) may be fixedly connected to the respective lower side wall portion (or upwardly upright base side wall) (546) (a and b) and end wall portion (or upwardly upright end wall portion) (548) (a and b) of the shallow base by, for example, riveting or welding, to form a box-shaped structure. Likewise, the ends of the C-shaped fold are fixedly connected together to form the upper part of the metal container body, which is then fixedly connected to the lower part of the metal container body (512). Specifically, the ends of the C-shaped fold are connected together by overlapping one end with the other end. The ends are fixedly connected together, for example, by welding or riveting the ends together or using adhesive.

[0069] An alternative to the embodiment of the metal container body shown in FIGS. 11 (a and b) and 12 is the embodiment shown in FIGS. 13 (a and b), in which the side walls (670) (a and b) and end walls (672) (a and b) in the upper portion of the metal container body (612) are held together by one or more retainers (674, 676). As with the other embodiment shown in FIGS. 11 (a and b) and 12, the upper portion of the metal container body can be folded in that it is erected from a folded sheet metal blank. Two sheet metal blanks (650) (a and b) are shown, wherein each of the two sheet metal blanks (650) (a and b) can be folded to define side walls (670) (a and b) and end walls (672) (a and b) having a length extending along the length of each side wall and end wall of the metal container body (612). In other words, each of the two sheet metal blanks (650) (a and b) can be folded to define a substantially L-shaped structure. The two L-shaped structures are brought together to form a tubular structure configured to be mounted in a shallow base of the lower part. 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 a specific embodiment shown in FIG. 13a, one or more retainers include C-shaped channel tubes (676) at mutually opposite ends of the metal container body to secure the folded sheet metal blanks together. During the assembly of the metal container body as shown in FIG. 13b, 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), one or more retainers include separate rim portions (674) configured to be mounted on the upper edges of the folded sheet metal blanks (650) (a and b) to define the rim of the metal container body (612).This separate rim portion serves a dual purpose: to secure the folded sheet metal blanks together and to provide a bonding surface for the grabber device of the load handling device to bond with the rim of the metal container body. One or more retainers (674, 676) may be cast to increase the strength of the metal container body. The upper portion may be a cast metal plate rather than being formed from foldable sheet metal blanks that can be pivotably connected together.

[0070] In the embodiments shown in FIGS. 11 (a and b), FIGS. 12 and FIGS. 13 (a and b), the upper side wall portions are pivotally connected to each end wall portion, for example, by a bow hinge. Instead of having a sheet metal blank containing side wall portions pivotally connected to each end wall portion, the mutually opposing side walls (770) (a and b) and end walls (772) (a and b) of the metal container body (712) may be formed as separate portions that are assembled together. In the exemplary seventh embodiment of the invention shown in FIGS. 14 (a and b), the walls of the upper portion (770 (a and b), 772 (a and b)) are formed as separate portions, for example by stamping, and then fixedly connected together to form the upper side wall portion and the upper end wall portion. The connection of the separate wall portions of the upper portion may be made by a snap-fit ​​joint. The separate parts of the upper portion are also fixedly connected to the lower mutually opposing sidewall portions (746) (a and b) and the lower end wall portions (748) (a and b) of the lower portion. In the same folded or disassembled state as shown in FIG. 14a, the separate parts of the upper portion can be conveniently placed within the shallow base (744) of the lower portion in the folded state, so that the storage container occupies less storage space for transport. The separate upper sidewall portions (770) (a and b) and end wall portions (772) (a and b) can be stamped from sheet metal blanks and generally have a thickness of 0.5 mm to 1 mm. As with other embodiments of the invention shown in FIG. 11 (a and b) through 13, the lower portion is formed by a deep drawing process or stamped from a sheet metal blank. At the point of use, the separate side wall portions (770) (a and b) and end wall portions (772) (a and b) of the upper portion can be connected to the lower portion, for example by a snap-fit ​​joint, to create a box-shaped structure as shown in FIG. 14b.The upper edge of the shallow base includes a connecting portion (750) that snaps into the corresponding connecting portion of the upper sidewall portion and the endwall portion. In a specific embodiment shown in FIG. 14 (a and b), the connecting portion is integrally formed within the sidewall portion and the endwall portion 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 holes or openings in the rim of the metal container body to be coupled with the grabber device of the load handling device. In use, separate walls including the sidewall portion (770) (a and b) and the endwall portion (772) (a and b) can be individually fixed to the wall of the shallow base (744), so that each of the mutually opposing sidewalls of the metal container body includes a lower sidewall portion and an upper sidewall portion. Similarly, each of the mutually opposing endwalls of the metal container body includes a lower endwall portion and an upper endwall portion.

[0071] In another exemplary variation of the seventh embodiment of the invention shown in FIG. 14c, separate upper sidewall portions (771) (a and b) and upper endwall portions (773) (a and b) can be releasedly connected together by a releaseable latch mechanism to enable rapid assembly and disassembly of the metal container body (711) from the shallow base (744). The separate portions of the upper portion are fixedly connected to the lower mutually opposing sidewall portions (747) (a and b) and lower endwall portions (749) (a and b) of the lower portion (744). In a specific embodiment shown in FIG. 14c and more clearly shown in FIG. 14d, the upper sidewall portions (771) (a and b) and the upper endwall portions (773) (a and b) are connected so as to be released together by the mutual cooperation of a hook and a toggle latch (760) at each distal or mutually opposite end of the upper sidewall portion and the upper endwall portion. As shown in FIG. 14c, the mutually opposite ends of the upper sidewall portions (771) (a and b) include one or more toggle latches (760) configured to cooperate with the hooks at the mutually opposite ends of the upper endwall portions (773) (a and b). Two toggle latches (760) are shown to be spaced apart from each other at the mutually opposite ends of the upper sidewall portions (771) (a and b). The assembly of the metal container body comprises providing the upper side wall portion and the end of the end wall portion together and fixing them together with a toggle latch. The present invention is not limited to two toggle latches located at mutually opposing ends of the upper side wall portion, and any number of toggle latches may be included at mutually opposing ends of the upper side wall portion. Likewise, the toggle latches do not necessarily have to be located at mutually opposing ends of the upper side wall portion, but may be located at mutually opposing ends of the upper end wall portion. The advantage of the releaseable latch is that it enables rapid assembly and disassembly of the metal container body (711).Individual wall sections (771(a and b), 773(a and b)) can be formed from sheet metal blanks, for example, stamped or cast as metal plates.

[0072] In other examples of metal container bodies shown in FIG. 14 (a to d), separate wall sections of the metal container body can be stacked for storage or transport. In a specific embodiment shown in FIG. 14e, multiple separate sections of the metal container body can be conveniently stacked (780) and thus occupy less storage space than when assembled. Additionally, by having separate sections that are assembled together at the point of use, if any of the separate sections are damaged, they can be easily replaced or exchanged, that is, separate sections of the metal container body can be provided.

[0073] In another variant of the metal container body shown in FIG. 15 (a to e), the metal container body (790) is formed by a two-stage forming process comprising a deep drawing process combined with separate mutually opposing side walls and end walls. Similar to the embodiment shown in FIG. 14 (a to e), the walls of the upper portion of the metal container body are formed as separate parts, for example by stamping, and then fixedly connected together to form the upper side wall portion (794) and the upper end wall portion (795). As with the other embodiment of the invention shown in FIG. 14 (a to e), the separate mutually opposing side walls (794) and mutually opposing end walls (795) are reinforced to relieve twisting of the metal container body (790) when assembled together. Similar to the embodiment shown in FIG. 13 (a and b), one or more distinct rim portions (798, 799) are mounted on the upper edges of the upper side wall portion (794) and the upper end wall portion (795) to define the rim of the metal container body (790). However, unlike the embodiment shown in FIG. 13 (a and b), distinct rim portions (798, 799) are mounted on each of the upper side wall portion (794) and the upper end wall portion (795). The rim portions (798, 799) include one or more openings or holes (810, 811) for engaging with the grabber device of the load handling device. The profile of the rim portions (798, 799) works in conjunction with the upper side wall portion (794) and / or the end wall portion (795) to form an elongated hollow portion (802, 805). The elongated hollow portion (802, 805) is located below one or more openings or holes (810) in the rim portion, and the elongated hollow portion extends along the entire length of the rim portion (798, 799) and is positioned to accommodate the gripper element of the grabber device.In detail and as shown in FIG. 15(c and d), the upper side wall portion (794) and the end wall portion (795) of the metal container body (790) are formed from a single skin or sheet metal blank, and optionally can be formed by stamping a sheet metal blank. The rim portion (798, 799) can be equally formed from a single skin or sheet metal blank. The upper edge of the rim portion (798, 799) is turned inward to form a lip (815, 816) having one or more holes or openings (810, 811) for engaging with the grabber device of the load handling device. The elongated hollow portion (802, 805) of the rim portion (798, 799) is located below the lip (815, 816). As shown in FIG. 15 (c and d), one or more depressions or curves (803, 804) are formed on the upper edge of the upper side wall portion (794) and / or the upper end wall portion (795), and when the rim portion is mounted on the upper side wall portion (794) and / or the upper end wall portion (795) to define a cavity for accommodating a gripper element of a grabber device as shown in FIG. 5 and 6, the depressions or curves are positioned to cooperate with one or more holes or openings (810, 811) in the rim portion (798, 799). Additionally, the depressions or curves (803, 804) are positioned between a pair of protrusions (800, 801) formed on the upper edge of the upper side wall portion (794) and / or the upper end wall portion (795). Specifically, the recess or curve (803, 804) and a pair of protrusions (800, 801) of the upper edge of the upper side wall portion (794) and / or upper end wall portion (795) are designed to fit into the elongated hollow portion (802, 805) of the rim portion (794, 795), as shown in FIG. 15b.Additionally, the rim portions (798, 799) are configured to be clipped or snap-fitted to the outside of the upper side wall portion (794) and / or the upper end wall portion (795). As shown in FIG. 15 (c and d), the upper edge of the upper side wall portion (794) and / or the upper end wall portion (795) has two recesses or curves (803, 804) and two pairs of protrusions (800, 801) located adjacent to each corner of the metal container body (790). Similarly, there are two holes or openings (810, 811) located in the rim portions (798, 799) shown in FIG. 15(c and d), which are positioned adjacent to each corner of the metal container (790) and aligned perpendicularly with two depressions or curves (803, 804) in the upper side wall portion (794) and / or upper end wall portion (795). By this arrangement, a good connection is ensured between the rim portions (798, 799) and the upper side wall portions (794) and / or upper end wall portions (795) along the length of the upper side wall portions (794) and / or upper end wall portions (795), particularly around the area interacting with the gripper device. To improve the structural integrity of the box-shaped structure of the metal container body and to allow the upper side wall portion and the end wall portion to be fixed together, one or more flanges (806, 807) are formed at mutually opposing ends of the upper side wall portion (794) and the upper end wall portion (795). When the upper side wall portion and the upper end wall portion are brought together with the lower portion (791) of the metal container body to form a box-shaped structure, the flange (807) of the upper end wall portion (795) is configured to overlap the adjacent flange (806) of the upper side wall portion (794). For example, the flange (807) of the upper end wall portion (795) is configured to overlap the adjacent flange (806) of the upper side wall portion (794). This is illustrated in FIG. 15e.Each flange of an adjacent upper sidewall portion or upper endwall portion extends across the corner of the metal container body to reinforce the corner. Various fasteners known in the art may be used to secure the upper sidewall portion (794) and the endwall portion (795) together at the corner of the metal container body using their respective flanges. This includes, but is not limited to, welding, e.g., spot welding, riveting, and / or the use of adhesives. In a specific embodiment of the invention, the flanges (806, 807) of the upper sidewall portion (794) and the endwall portion (795) are secured 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 metal sheets using special punches and dies to create a physical interlock between the sheet metal layers. To further improve the structural integrity of the box-shaped structure, the rim portion (798) mounted on the upper end wall portion (795) also includes a rim flange (812) at each corner that overlaps the flange (807) of the upper end wall portion (795).

[0074] In order to allow the gripper element of the grabber device to be properly aligned with the hole or opening (810, 811) in the rim portion of the storage container, the metal container body includes a guide (796) at each corner of the box-shaped structure of the metal container body, which extends vertically from the upper edge at least partially along the height of the box-shaped structure to accommodate the guide pin or positioning pin of the grabber device. As described above with reference to FIG. 6, the guide (796) is formed to cooperate with the guide pin or positioning pin of the grabber device to properly align the gripper element (62) with the opening (810, 811) in the rim portion (798, 799) of the storage container. The guide (796) at the corner of the metal container body is formed by an elongated vertical recess in the flange (807) of the upper side wall portion (794) and / or end wall portion (795). An elongated vertical depression (796) may be formed by one or more curves in the sheet metal of the upper side wall portion (794) and / or the upper end wall portion (795). In a specific embodiment of the invention, the elongated vertical depression (796) is formed in the flange (807) of the upper end wall portion (795) as shown in FIG. 15d. A corresponding elongated depression (813) is formed in the rim portion (798) mounted on the upper end wall portion (795), which is formed to cooperate with the elongated vertical depression (796) formed in the flange (807) of the upper end wall portion (795) as shown in FIG. 15d. The long vertical recess (796) in the flange (807) of the upper end wall portion (795) is configured to overlap the flange (806) of the upper side wall portion (794) at the corner of the box-shaped 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 FIG. 15e.The overlapping flanges (806, 807) of the upper side wall portion (794) and the upper end wall portion (795) together with the overlapping elongated vertical recess (813) in the flange (812) of the edge portion (798) provide a corner of the metal container body (790) having three overlapping layers. In this way, the corner of the metal container body (790) is reinforced to support the load from one or more storage containers placed on top when a storage container, particularly one containing the metal container body, is placed in a stack of storage containers. Thus, rigidity exists through the corner of the metal storage container (790) from the three-part corner structure shown in FIG. 15e. The edge (797) of the edge portion in the corner portion of the metal container body is profiled to wrap around the flange (806) of the upper side wall portion, thereby improving the connection of the edge portion to the upper side wall portion.

[0075] In the ninth embodiment of the metal container shown in FIG. 16, the metal container body (818) comprises a deep-drawn base portion (820), an upper side wall portion (822), and an upper end wall portion (824). A rim portion (823, 825) is mounted on each of the upper side wall portion (822) and the upper end wall portion (824). The deep-drawn base portion (820) includes an embossed pattern within the bottom wall of the container to increase the rigidity of the base portion and also increase the grip on the roller below in the conveying system. In FIG. 16, the embossed surface includes a hexagonal pattern, but any kind of pattern, such as a square pattern as shown in FIG. 17b, may be used. 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 portion (820). As shown in FIG. 16, this means that both the flange (821) of the rim portion (825) and the flange (827) of the upper end wall portion (824) provide increased rigidity along the entire vertical length of the corner of the metal container body (818). FIG. 16 also indicates that the metal container includes a cut (819) in each of the upper side wall portions (822). The cut section (819) is surrounded and reinforced by a rim section (823) to provide increased rigidity, and the rim section (823) extends downward from both sides of the cut section (819) so that the rim section (823) has a vertical height greater than the height of the cut section (819). By having the cut section (819) in each of the upper side wall sections (822), the metal container body (818) can be used to hold a delivery tote.

[0076] The metal container shown in FIG. 16 also includes a corner piece or foot (826) that fits into the corner of the deep-drawn base portion (820). The corner piece (826) allows the delivery tote to be seated inside the metal container body (818) at a height suitable for the delivery tote machine.

[0077] In contrast to the metal storage container shown in FIG. 15 and 16, which includes four rim portions, the metal storage container (828) shown in FIG. 17 includes two rim portions (834), and these rim portions are mounted on each upper end wall portion (836). The rim portion (834) is shown in more detail in FIG. 17c and includes an elongated central portion (837) and two recesses (838) on both sides of this elongated central portion. The two recesses (838) allow a gripper device to engage with 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 (839) helps to support the container bottom wall of the base portion (830) of the adjacent storage container above in the stack. These adjacent storage containers are also supported by a normal edge return (831) at the upper edge of the upper end wall portion, which will be discussed briefly. Although the rim portion (834) is shown as a single component in FIG. 17c, it may also be formed as two equally formed components joined and spot-welded together in the middle of the elongated central portion (837).

[0078] The rim portion (834) is configured to be fitted onto the normal edge return (831) located at the upper edge of the upper end wall portion (836). The normal edge return (831) has a width of approximately 20 mm and is configured to connect with the elongated central portion (837) of the rim portion (834) and to allow access for the gripper device to connect with the metal storage body (828) through the recess (838) of the rim portion (834). The rim portion (834) is fitted onto and secured onto the normal edge return (831) using spot welding. Spot welding is also used to secure other parts of the metal storage body together, for example, as shown in FIG. 17a, the upper end wall portion (836) is attached to the base portion (830) by three spot welds (833) and the upper side wall portion (832) is attached to the base portion (830) by four spot welds, but the upper side wall and / or end wall may be connected by any number of spot welds, e.g., 2, 5, 6, 7, 8, or 9 spot welds. Specifically, the upper end wall portion (836) and the upper side wall portion (832) are attached to the upwardly upright base side wall portion and end wall portion of the base portion.

[0079] The upper side wall portion (832) and the upper end wall portion (836) include ribs or beaks (835) formed by forming metal. The ribs or beaks (835) are located near the base of the upper side wall portion (832) and the end wall portion (836). The ribs or beaks (835) increase the rigidity of the upper end wall and side wall portions (832, 836). As shown in FIG. 17a, the ribs or beaks (835) are symmetrically arranged along the length of the upper side wall portion (832) and the upper end wall portion (835). The ribs or beaks (835) minimize movement of the upper side wall portion (832) and the end wall portion (836) when assembled into a box-shaped structure. As shown in FIG. 17a, three ribs or beaks (835) are located in the upper end wall portion (836), and seven ribs or beaks are located in the upper side wall portion (832). Any number of ribs or beaks are present in the upper side wall portion (832) and the upper end wall portion (836), for example, four, five, six, eight, or nine ribs or beaks in each upper side wall portion (832) and / or end wall portion (836).

[0080] Each upper side wall 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. 17d, when the upper side wall portion (832) and the upper end wall portion (836) are positioned within the base portion (830) to form a box-shaped structure (828), each flange (840a, 840b) overlaps on or under another adjacent flange. FIG. 17d specifically shows the flange (840b) of the upper side wall portion (832) located inside the flange (840a) of the upper end wall portion (836). This structure, in which one flange overlaps another flange, reinforces the corner and provides greater vertical structural rigidity. In contrast to the corner shown in FIG. 15e, the corner of this embodiment includes two portions rather than 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 portion (830) by placing the upper side wall (832) or the upper end wall (836) within the base side wall or end wall (841) as shown in FIG. 17e and spot welding the two respective walls together.

[0081] Additionally, the metal storage container (828) includes holes in one or more flanges of the upper side wall portion or the end wall portion. As shown in FIG. 17a, holes (839) are located in each flange (840a) of the upper end wall portion (836). Alternatively, or additionally, one or more holes may also be located in each flange (840b) of the upper side wall portion (832). The one or more holes (839) can be used as positioning tools so that the metal storage container (828) can be positioned accurately and repeatedly in the same location if necessary.

[0082] This embodiment uses a barcode (not shown) located on the outside of a metal storage container to help verify the position and alignment of the container, for example, in a delivery tote machine. This is an alternative to the use of corner pieces or issuances as used in the embodiment of FIG. 16.

[0083] The eleventh embodiment of the 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) located in each upper side wall portion (845). This recess (843) is C-shaped and has a size and shape that allows an alignment tool to be inserted into the recess (843), thus ensuring accurate alignment of the metal storage container, for example, in a delivery tote machine. Similar to the embodiment shown in FIG. 16, the metal storage container (842) of the eleventh embodiment includes an incision (847) in each upper side wall portion (845). By having an incision (847) in each upper side wall portion (845), the metal container body (842) can be used to hold a delivery tote.

[0084] FIGS. 14 through 18 illustrate other embodiments of a metal storage unit having an upper side wall portion and an end wall portion separate from the base portion. Alternatively, the upper side wall portion (870) (a and b) and the end wall portion (872) (a and b) of the metal container body (860) may be pivotally attached to the corresponding lower side wall portion (846) (a and b) and end wall portion (848) (a and b) of the hollow base or tray (844) by a hinge (880), such as a bow hinge, as shown in the exemplary 12th embodiment of the invention in FIG. 19 (a and b). At the point of use, the upper side wall portions (870) (a and b) and the end wall portions (872) (a and b) are rotated around their respective pivotable connecting portions (880) as shown in FIG. 19b, so that adjacent ends of the upper side wall portions (870) (a and b) and the end wall portions (872) (a and b) are joined to form a box-shaped structure. The joint between adjacent ends of the upper side wall portions (870) (a and b) and the end wall portions (872) (a and b) can be made by the use of a snap-fit ​​joint, welding, riveting, or even adhesive. As with other embodiments of the invention described above, the upper edges of the side walls and end walls at the perimeter of the metal container body are turned inward to form a lip or flange (866) for releaseable connection with a grabber device.

[0085] Alternatively, the mutually opposing ends of the upper sidewall portions (970) (a and b) and the endwall portions (972) (a and b) may be joined together at the corners of the metal container body (912) by one or more corner posts (930), as shown in the exemplary 13th embodiment of the invention in FIG. 20 (a and b). The corner posts (930), which may be cast, provide structural integrity so that the walls of the metal container body (912) do not buckle when stacked with other storage containers in a grid framework structure. In the assembled state as shown in FIG. 20b, the sidewalls of the metal container body (912) include the lower sidewall portions (946) (a and b) and the upper sidewall portions (970) (a and b). Similarly, the end wall of the metal container body (912) includes a lower end wall portion (948) (a and b) and an upper end wall portion (972) (a and b).

[0086] Similar to other embodiments of the present invention shown in FIGS. 14 (a and b) to FIGS. 20, the base sidewall portion and the base endwall portion of the shallow base are inclined outward from the bottom wall of the container, so that a plurality of metal container bodies can be stacked vertically on top of each other for ease of transport, as shown in FIG. 21. In the 12th and 13th embodiments shown in FIGS. 19 and 20, by pivotally attaching the upper sidewall portion and the upper endwall portion to the respective lower sidewall portion and lower endwall portion of the shallow base, parts of the metal container body are prevented from being lost during transport, and easy assembly of the metal container is possible at the point of use.

[0087] In contrast to forming the metal container body with a deep-drawn base and one or more folded sheet metal blanks, the base and upper portion of the metal container body may be formed from one or more patterned sheet metal blanks, as shown in the 14th and 15th embodiments of the present invention shown in FIG. 22 and 23. For the storage of food products, one or more flanges may be bent or folded at the edges of the sheet metal blanks, so that when erected, the flanges help to seal the joint between adjacent side walls and end walls of the metal container body to keep the side walls and end walls together in an upright position and also to prevent fluid from escaping from the metal container body. Alternatively, or in addition to providing flanges at the joint between adjacent walls (side walls and end walls) of the metal container body, the internal space within the metal container body may include a polymer liner or an inner container to contain any leakage escaping from the contents of the storage container.

[0088] In the exemplary 14th embodiment of the present invention shown in FIG. 22 (a and b), the 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 wall (1016) (a and b) and end wall (1018) (a and b) of the metal container body (1012). By erecting the metal container body (1012) from one or more sheet metal blanks (1050) (a and b), the advantage is obtained that the metal container body can be flattened for ease of transport and storage. In a specific embodiment shown in FIG. 22a, the metal container body (1012) is formed by a main section (1050a) forming the container bottom wall (1015) and mutually opposing side walls (1016) (a and b) of the metal container body (1012), and a separate end plate (1050b) forming the end wall (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 dotted line) extending perpendicular to the longitudinal direction of the main section (1050a). At the point of use, the main section (1050a) of the sheet metal blank is folded along the folding line (1052) to form the container bottom wall (1015) and the mutually opposite side walls (1016) (a and b) of the metal container body (1012) having mutually opposite open ends, that is, the mutually opposite side walls are folded so that they are substantially perpendicular to the container bottom wall. Then, the end plate (1050b) is used to cover the mutually opposite open ends, forming a box-shaped structure as shown in FIG. 22b. The edge or distal end of the main section (1050a) and / or the end plate (1050b) is folded to form a flange (1054) for securing the end plate (1050b) to the folded main section (1050a) of the sheet metal blank, that is, for securing the end plate (1050b) to the side walls (1016) (a and b).In a specific embodiment of the invention shown in FIG. 22, the mutually opposing edges of the main section of the sheet metal blank are extended to form a flange (1054). The end plate (1050b) may be secured to the flange (1054) of the sheet metal blank (1050a) by welding, the use of adhesive, or other fastening means. In a specific embodiment shown in FIG. 22b, the end plate (1050b) is fixedly attached to the flange (1054) of the sheet metal blank (1050a) by riveting. As with other embodiments of the invention described above, the main section (1050a) and / or the end plate (1050b) may include one or more vent holes (1020) that can be stamped into each sheet metal blank (1050a) or end plate (1050b) to create vent holes (1020) and / or handles. At least one edge or end of the main section and end plate of the sheet metal blank may be turned inward or outward to create a rib (1064) on the periphery of the assembled box-shaped structure as shown in FIG. 22b. As in other embodiments of the invention, the rib (1064) on the periphery enables the grabber device of the load handling device to engage with the metal container body when lifting the storage container from the stack.

[0089] Alternatively, the metal container body (1112) may be formed as a single part, more specifically, as in the exemplary 15th embodiment shown in FIG. 23 (a and b), from a single sheet metal blank (1150). As shown in FIG. 23a, the sheet metal blank (1150) comprises a central section forming the container bottom wall (1115) and mutually opposing side walls (1116) (a and b), and end wall (1118) (a and b) sections attached to the central section (1115), for example, by a bow hinge. Erecting the metal container body involves folding the mutually opposing side walls and end wall sections (1116) (a and b) at a substantially right angle to the container bottom wall section (1115) to create a box-shaped structure as shown in FIG. 23b. The sheet metal blank (1150) may include a folding line (1152) to assist in folding the mutually opposing sidewall and endwall sections. The edges of the sidewall and / or endwall and / or container bottom wall sections may be folded to create a flange for joining the walls of the metal container body together and also provide a leak-proof container body. Alternatively, the internal space within the metal container body may include a polymer liner or an inner container to contain leaks from the storage container. One or more retainers may be used to hold the mutually opposing sidewalls and endwalls in a vertical position. Likewise, the upper edges or ends of the mutually opposing sidewalls and endwalls may be turned, for example, inward or outward, to form a lip (1164) at the rim of the box-shaped structure. This rim includes one or more openings (1160) that allow a grabber device to join with the metal container body. As with other embodiments of the metal container body, one or more ventilation holes (1120) may be cut and formed in the sheet metal blank by, for example, stamping or other means so that air can circulate inside the metal container body.

[0090] In all embodiments in which a sheet metal blank is used to produce a metal container body, for example by a deep drawing process or by folding the sheet metal blank as described with reference to FIGS. 8 through 23, the sheet metal blank may be coated with a polymer lining in a laminated structure. This is particularly important when the contents of the storage container contain food to prevent contamination of the food from exposure to the metal container body. Additionally, the sheet metal blank may be corrugated, for example by stamping, by forming one or more ribs on the sheet metal blank to improve the structural integrity of the erected metal container body.

[0091] In another exemplary embodiment of the present invention, a metal container body (1212) comprising a container bottom wall (1215), mutually opposing side walls (1216) (a and b) and end walls (1218) (a and b) may be cast as a single monolithic body. For example, the metal container may be die-cast or alternatively cast by an investment casting process. In the 16th exemplary embodiment of the present invention shown in FIG. 24, the metal container body (1212) is die-cast as a single monolithic body. Although it does not provide a foldable storage container as in the other embodiments discussed above, casting the metal container body as a single monolithic body improves strength in a single part, thereby preventing buckling of the walls of the metal container body when the metal container body is placed in a stack. The metal container body may be cast from aluminum having a wall thickness of about 1 to 1.5 mm. However, the metal container body may be cast using other lightweight metals. Another advantage of casting the metal container body is that it can provide a leak-proof container to prevent fluid from leaking out of the storage container.

[0092] The vent hole (1220) may be formed on-site during the casting of the metal container body, or alternatively, the vent hole may be machined into the wall of the metal container body once it has been cast. The vent hole (1220) may be positioned at a predetermined height above the bottom wall of the container to provide a leak-proof base for catching spills. Optionally, one or more ribs (1222) may be cast into the walls (side walls and end walls) of the metal container body (1212) to improve the structural integrity of the metal container body so that it can withstand loads when the metal container body is in a stack.

[0093] In another embodiment of the invention described above, the walls of the metal container body are generally solid in that they are composed of solid material, and may also include a coating or be laminated to ensure that the inner surface of the metal container body is safe for food. One or more wall reinforcements and / or inserts and / or corner posts may be incorporated into the metal container body to improve the structural integrity of the storage container. In another exemplary embodiment of the invention, the walls of the metal container body may be made hollow to accommodate auxiliary filler. In the 17th exemplary embodiment of the invention shown in FIG. 25, the mutually 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 spaces within the walls of the metal container body may be filled with filler to improve the properties of the metal container body (1312). For example, the filler may be a polymer foam that provides soundproof acoustic properties to the storage container. Optionally, the filler may be fire-resistant. Typical fire-resistant materials that are lightweight and fire-resistant include, but are not limited to, vermiculite. The filler may also improve the structural properties of the storage container so that it can withstand loads when held in a stack. Although not shown in FIG. 25, one or more ribs may be formed on the walls of the storage container to improve the structural integrity of the storage container. Joints between adjacent side walls and end walls may be secured together by welding, the use of adhesive, rivets, or simply tongue-groove joints. The container bottom wall, side walls, and end walls may be separate parts assembled together at the point of use for ease of transport.

[0094] If the contents of a storage container are food items, they must be stored in a container that complies with food safety standards. The types of metals that can be used to manufacture metal container bodies that comply with food safety standards are limited. Such metals include various stainless steel materials, such as 304 stainless steel. However, when manufacturing metal container bodies from stainless steel, there is a problem in that the metal is less dense than other types of metals, such as lower-grade steel or aluminum, and is also generally more expensive. Consequently, the walls of a metal container body will be relatively thin compared to its plastic counterpart with a similar weight in the industry. The area of ​​a storage container vulnerable to fire is its outer surface. Since metal container bodies are fire-resistant, they can function as a fire-resistant body that forms a non-combustible enclosure to prevent or limit the entry of fire into the interior space of the storage container. Because the metal container body can function as a non-combustible enclosure and to comply with food safety standards for food storage, the fire-resistant body may include a liner formed from food-grade materials. 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. To make the liner moisture-resistant, the paper or cardboard liner may be impregnated or coated with food-safe wax. At least a portion of the inner surface of the fire-resistant body comprises a liner (1420, 1422) formed of food-safe or grade material in such a way that the height of the liner (1420) partially extends along the full height of the metal container body (1412) as shown in FIGS. 26 and 27 or along the full height of the metal container body (1412) as shown in FIGS. 28 and 29.By using a liner (1420, 1422) suitable for food storage, different materials may be used for the refractory body. In the specific embodiment described above, the refractory body (1412) may comprise metal, or other refractory materials may be used in the manufacture of the refractory body, such as various ceramic materials and various refractory plastic materials, such as plastic materials containing refractory additives. This refractory body may comprise low-density materials but possesses the same structural integrity and load-bearing capacity as current plastic storage containers. Consequently, the walls of the refractory body may be made thicker so that sufficient load-bearing capacity can be provided to the walls of the storage containers to support the weight of multiple storage containers in a stack.

[0095] In a specific embodiment of the invention shown in FIG. 26, the fireproof body comprises a metal container body (1412) comprising a bottom wall (1415), upwardly upright mutually opposing side walls (1416a, 1416b), and end walls (1418a, 1418b). 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 of food-grade material and is leak-proof to prevent the leakage of juices from food products such as meat. There are various examples of forming a leak-proof liner. Examples include, but are not limited to, blow molding and thermoforming of a single-piece liner when the liner comprises food-grade plastic material. If the liner comprises a cellulose-based material such as paper or cardboard, the liner may be formed from a foldable sheet blank impregnated or coated with a wax material. The height of the liner needs to extend over the entire height of the metal container body, or it may extend partially along the entire height of the metal container body. In the example shown in FIG. 27, the height of the tray (1420) extends over half the height of the metal container body (1412). This is considered acceptable when the food stored in the storage container contacts only the bottom wall of the storage container and partially contacts the mutually opposing side walls and end walls of the storage container, and / or is necessary only to prevent leakage of food juices that contaminate other food in nearby storage containers. However, this does not mean that the liner can extend over the entire height of the metal container body. FIGs. 28 and 29 show an example where the liner (1422) extends over the entire height of the metal container body (1412).In this case as well, the liner (1422) functions as an insert placed inside the metal container body as shown in FIG. 28.

[0096] By having a liner based on paper or cardboard, the liner becomes disposable, allowing different types of food to be stored in the metal container body, and limiting the need to continuously clean the inner surface of the storage container. If the storage container comprises a metal container body, particularly low-grade steel, using water to clean the storage container tends to cause the metal container body to corrode or rust, rendering it unusable for storing food. By using a liner made of food-grade material, the need to clean the metal container body is eliminated, thereby extending the lifespan of the metal container body. Although preferred embodiments of the present invention have been described in detail above, it should be understood that various modifications of the storage container including the different features described above and different combinations of features described in relation to other embodiments are applicable within the scope of the present invention as defined in the claims.

[0097] Further features of the present invention may be described by referring to the following numbered clauses:

[0098] Clause 1. A storage container for storing one or more articles in a storage and retrieval system, wherein the storage and retrieval system comprises a track system comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks extending transversely to the first set of parallel tracks in a substantially horizontal plane to form a grid pattern comprising a first set of parallel rails or tracks and a plurality of grid spaces or grid cells, and a plurality of storage container stacks positioned below the track system, each of the plurality of storage container stacks occupying a single grid space or grid cell, and the first delay storage container comprises a container bottom wall, upwardly upright mutually opposing side walls and end walls arranged in a box-shaped structure having an open end for accommodating one or more articles inside the box-shaped structure, and

[0099] A storage container comprising a fireproof container body forming a non-combustible enclosure, and a liner formed of a food-grade material on at least a portion of the inner surface of the fireproof body.

[0100] Clause 2. In Clause 1, the fireproof container body is a storage container in which the container body is a ceramic container body.

[0101] Clause 3. In Clause 1, the fire-resistant container body is a storage container in which the container body is a plastic container body.

[0102] Clause 4. A storage container in which, in any of the preceding clauses, at least one of the upwardly standing mutually opposing side walls and / or end walls is detachable.

[0103] Clause 5. In any of the preceding clauses, a storage container in which the liner comprises food-grade plastic material and / or cellulose-based material.

[0104] Clause 6. A storage container in which the cellulose-based substrate of Clause 5 is coated or impregnated with a wax material.

[0105] Clause 7. A storage container in Clause 6, wherein the cellulose-based material is paper or cardboard.

[0106] Clause 8. In Clause 7, the liner is a storage container formed from folded paper or cardboard blanks.

[0107] Clause 9. In any of the preceding clauses, a storage container in which the liner is disposable.

[0108] Clause 10. In any of the preceding clauses, the liner is a shallow donation or tray, or a storage container.

[0109] Clause 11. In any of the preceding clauses, the liner is a leak-proof container, a storage container.

[0110] Clause 12. In Clause 11, the leak-proof container is a storage container that is a monolithic thermoformed container.

Claims

Claim 1 A storage container (828) for storing one or more items in a storage and retrieval system, wherein the storage and retrieval system comprises a track system comprising a first set of parallel rails and a second set of parallel rails extending transversely to the first set of parallel rails in a horizontal plane to form a grid pattern comprising a first set of parallel rails and a plurality of grid spaces, and a plurality of storage container stacks located below the track system, each of the plurality of storage container stacks occupying a single grid space, and the storage container comprises a metal container body (829), wherein the metal container body comprises a base portion (830) formed as a single unit body and having a container bottom wall (814) and an upwardly upright base side wall portion and base end wall portion (841) to form a tray, and a separate upper side wall portion (832) and upper end wall portion (836) extending upward from and connected thereto from each base side wall portion and base end wall portion (841) of the base portion to form a box-shaped structure having an open end for accommodating one or more items within a box-shaped structure. A storage container comprising an upper portion, 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-shaped structure, and the rim portion comprises one or more openings or recesses (838, 811) for coupling with a grabber device of a load handling device. Claim 2 In claim 1, the base portion (830) of the metal container body is formed from a deep-drawn sheet metal blank, forming a storage container. Claim 3 In claim 1, the rim portion (834, 798) comprises a protruding lip (849, 816) that is directed inward or outward from the upper side wall portion and / or upper end wall portion to support the container bottom wall of an adjacent storage container located above in the stack. Claim 4 A storage container according to claim 1, wherein the rim portion is separately connected to the upper side wall portion and / or upper end wall portion. Claim 5 A storage container according to claim 1 or 2, wherein each corner of the metal container body comprises a plurality of overlapping layers. Claim 6 A storage container according to claim 1 or 2, wherein the upper side wall portion is separately fixed to the upper end wall portion. Claim 7 A storage container according to claim 6, wherein each of the upper side wall portion and / or upper end wall portion comprises at least one flange (806, 807) for fixably connecting the upper side wall portion to the upper end wall portion. Claim 8 In claim 7, a storage container configured such that each flange (806, 807) overlaps on or under an adjacent flange. Claim 9 In claim 7, the storage container further comprises guides (796) at each corner of the storage container for alignment of the grabber device of the load handling device. Claim 10 In claim 9, the guide (796) is formed as an elongated vertical depression in the flange (807) of the upper side wall portion and / or the upper end wall portion, in a storage container. Claim 11 A storage container according to claim 1 or 2, wherein the donation portion comprises one or more patterns embossed within the bottom wall of the container. Claim 12 In claim 1 or 2, the storage container comprises a liner (1420, 1422) formed of food-grade material. Claim 13 In claim 12, the storage container comprising a liner made of food-grade plastic material and / or a cellulose-based material. Claim 14 In claim 13, the storage container wherein the cellulose-based material is coated or impregnated with a wax material. Claim 15 In Clause 12, the above-mentioned liner is a disposable storage container. Claim 16 In Clause 12, the liner is a shallow base or tray, a storage container. Claim 17 In claim 12, the liner is a storage container that is a leak-proof container. Claim 18 In claim 17, the leak-proof container is a storage container that is an integral thermoformed container. Claim 19 A kit for assembling a storage container according to claim 1, comprising: i) a base portion (830) formed as a single monolithic body and having a base side wall portion and a base end wall portion (841) that are upright and form a tray; and ii) a separate upper portion comprising an upper side wall portion (832) and an upper end wall portion (836). Claim 20 In claim 19, a kit for assembling a storage container further comprising: iii) two or more rim portions (837, 798, 799) separately connectable to the upper side wall portion and / or the upper end wall portion. Claim 21 A storage and retrieval system comprising: a track system including a first set of parallel rails and a second set of parallel rails positioned transversely to the first set of parallel rails within a horizontal plane to form a grid pattern including a plurality of grid spaces; and a plurality of stacked storage containers positioned below the track system; and includes a plurality of load handling devices, wherein each of the plurality of storage container stacks occupies a single grid space, and the plurality of storage container stacks includes a storage container comprising a metal container body, wherein the metal container body comprises a base portion formed as a single monolithic body and having a container bottom wall and an upwardly upright base side wall portion and base end wall portion to form a tray, and a separate upper portion having an upper side wall portion and an upper end wall portion extending upward from each base side wall portion and base end wall portion of the base portion and connected thereto to form a box-shaped structure having an open end to accommodate one or more items within a box-shaped structure, and wherein the plurality of load handling devices are supported and guided by parallel rails, and each load handling device comprises a container receiving space and a lifting mechanism, wherein the lifting mechanism is configured to lift at least one storage container from the plurality of storage container stacks into the container receiving space, and 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-shaped structure, and wherein the rim portion is one for coupling with a grabber device of the load handling device. A storage and retrieval system comprising the above openings or depressions (838, 811). Claim 22 In claim 21, the storage and recovery system, wherein the plurality of storage container stacks further include plastic storage containers. Claim 23 A storage and recovery system according to claim 21 or 22, wherein the storage and recovery system comprises one or more flame-resistant barriers, and the flame-resistant barrier comprises a plurality of metal storage container stacks. Claim 24 In claim 23, the one or more flame-resistant barriers surround a stack of multiple plastic containers, a storage and recovery system. Claim 25 delete Claim 26 delete Claim 27 delete

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