Storage system and storage container

Patent metadata

Field	Value
Publication number	US-2025381589-A1
Application number	US-202519242694-A
Country	US
Kind code	A1
Filing date	Jun 18, 2025
Priority date	Dec 22, 2022
Publication date	Dec 18, 2025
Grant date	—

Abstract

A method of manufacturing a storage container for storage in a stack in a grid framework structure comprising a plurality of storage columns, each of the plurality of storage columns being configured to store a stack of storage containers. The method comprises the steps of: forming a lower part of the storage container by the steps of: stamping or drawing a sheet metal blank into a drawing die to form a tray-shaped preform comprising a base with a raised rim and a flange; turning the flange to define a connection surface that extends in the same direction as the raised rim of the tray-shaped preform to form a container having a predefined depth; forming an upper part of the storage container by the step of: stamping sidewalls and/or end walls from one or more separate sheet metal blanks; attaching the lower part to the upper part by attaching the sidewalls and end walls to the connection surface of the container.

First claim

1 . A method of manufacturing a storage container for storage in a stack in a grid framework structure comprising a plurality of storage columns, each of the plurality of storage columns being configured to store a stack of storage containers, the method comprising the steps of:
A) forming a lower part of the storage container by the steps of: i) stamping or drawing a sheet metal blank into a drawing die to form a tray-shaped preform comprising a base with a raised rim and a flange; ii) turning the flange to define a connection surface that extends in the same direction as the raised rim of the tray-shaped preform to form a container having a predefined depth; B) forming an upper part of the storage container by the step of:
iii) stamping sidewalls and/or end walls from one or more separate sheet metal blanks;
C) attaching the lower part to the upper part by attaching the sidewalls and end walls to the connection surface of the container.

2 . The method of claim 1 , wherein the drawing die comprises a holding die member, an upper die member and a lower die member, at least one of the upper and lower die members comprising a punch and the opposite die member comprising a die cavity.

3 . The method of claim 2 , wherein the method further comprises the step of using the holder die member with the punch to control the amount of the sheet metal blank being drawn into the die cavity.

4 . The method of claim 2 , wherein the flange is turned by a wiping die comprising a location die member and a wiping die member, and wherein the method further comprising the steps of:
i) holding the pre-shaped preform in the location die member such that the flange extends outwardly from the location die member; ii) moving the wiping die member relative to the location die member to turn the flange.

5 . The method of claim 4 , wherein the wiping die member is ring shaped.

6 . The method of claim 4 , wherein the wiping die member is substantially rectangular.

7 . The method of claim 4 , wherein the wiping die member is integrally formed with the drawing die.

8 . The method of claim 4 , wherein the tray-shaped preform comprises flash extending from the raised rim of the tray-shaped preform and the method further comprises the step of trimming the flash to form the flange by a trim cutting die comprising a trim cutting punch and a location die member for supporting the tray-shaped preform, wherein the flash is trimmed by moving the trim cutting punch relative to the location die member to form the flange.

9 . The method of claim 8 , wherein the trim cutting punch is integrally formed with the drawing die.

10 . The method of claim 8 , wherein the method further comprises the step of trimming a corner of the flash by a trim corner cutting die comprising a corner cutting punch and a location die member for supporting the tray-shaped preform, wherein the corner of the flash is trimmed by moving the corner cutting punch relative to the location die member.

11 . The method of claim 10 , wherein the step of trimming the corner of the flash by a trim corner cutting die comprises the step of forming a notch in the corner of the flash.

12 . The method of claim 10 , wherein the corner cutting punch is integrally formed with the drawing die.

13 . The method of claim 1 , wherein the flange extends outwardly around the peripheral open edge of the raised rim and the flange is turned by inwardly turning the flange so that the flange extends in the same direction as the raised rim of the tray-shaped preform.

14 . The method of claim 1 , wherein the container in the lower part of the storage container is a shallow container.

15 . The method of claim 1 , further comprising the method of stamping a step into the flange.

16 . The method of claim 1 , wherein the sidewalls and end walls are attached to the connection surface by welding.

17 . (canceled)

18 . The method of claim 1 , wherein each of the sidewalls and/or end walls of the upper part of the storage container comprises one or more openings or depressions for engagement with a grabber device of a load handling device.

19 . The method of claim 1 , wherein the tray-shaped preform is stamped or drawn from the sheet metal blank comprising galvanised steel.

20 . A storage container for the storage of one or more items in a storage and retrieval system comprising a track system comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks running transversely to the first set of parallel tracks in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces or grid cells and a plurality of stacks of storage containers located beneath the track system and wherein each stack of the plurality of stacks of storage containers occupies a single grid space or grid cell, the storage container comprising a metallic container body formed by the method as defined in claim 1 .

21 . (canceled)

22 . A storage and retrieval system comprising:
i) a grid framework structure comprising a plurality of storage columns for the storage of one or more stacks of storage containers and a track system comprising a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells, the track system being arranged above the plurality of storage columns such that each of the plurality of storage columns is arranged below a respective grid cell of the track system;
ii) one or more stacks of storage containers, wherein at least one of the storage containers in the one or more stacks of storage containers being formed by the method as defined in claim 1 ;
iii) a plurality of load handling devices for lifting and moving storage containers stacked in the one or more stacks, the plurality of load handling devices being remotely operated to move laterally on the track system above the storage columns to access the storage containers through the grid cells, each of said plurality of load handling devices comprising:
a) a wheel assembly for guiding the load handling device on the track system;
b) a container-receiving space located above the track system; and
c) a lifting device arranged to lift a storage container from a stack into the container-receiving space.

Assignees

• Ocado Innovation Ltd

Inventors

• Aubusson Alastair
• Fernandopulle Ashan
• Hobbs Mark
• Bayliss Neil

Classifications

• B65G1/0478

  for matrix-arrangements · CPC title

• B65G1/0464

  with access from above · CPC title

• B65G1/026

  Racks equipped with a displaceable load carrying surface to facilitate loading or unloading · CPC title

• B21D51/52

  boxes, cigarette cases, or the like · CPC title

• B21D43/003

  Positioning devices (B21D28/04 and B21D28/265 take precedence; stops B21D43/26; centering moving strips B21D43/023) · CPC title