PARCEL SORTING SYSTEM, METHOD AND A CONTAINER THEREFOR

Abstract

A parcel sorting system is disclosed having bags located within rigid containers to form nested containers. The bags are configured to enable the bag to conform to an inner surface area of the rigid container. The resultant nested container can provide more efficient packing of packages and parcels for transportation.

Claims

1. A parcel sorting system, comprising: at least one collapsible flexible parcel holder and at least one container, the or each parcel holder including deployable elements, the or each parcel holder being configured to be locatable in a container, said deployable elements being configured and arranged so as to ensure external surfaces of the or each parcel holder substantially conform to internal surfaces of the container in which it is located, so as to create a combined, nested container, the nested container being configured and adapted so as to receive parcels in such a manner that packing density of parcels within the nested container will be maximized.

2. A parcel sorting system according to claim 1, in which each nested container comprises: parcels and packages for onward transportation to s discrete geographical location.

3. A method of maximizing packing density of a flexible parcel holder, the method comprising: presenting the flexible parcel holder to a container; locating the flexible parcel holder in the container; and deploying elements within the flexible parcel holder such that external surfaces of the flexible parcel holder conform to internal surfaces of the container so as to form a nested container.

4. A parcel sorting system, comprising: a presentation portion configured and arranged so as to present flexible parcel holders to rigid containers to create separable nested containers; a filling portion arranged so as to feed parcels and packages into said nested containers; a sealing and securing portion configured and arranged so as to substantially seal and secure said parcels and packages within the flexible parcel holder within the nested containers; and a separating portion configured and arranged so as to remove said sealed and secured flexible parcel holders from said containers.

5. A parcel sorting system as claimed in claim 1 comprising: a grid-based storage system arranged so as to store said containers in stacks within a framework, the framework having a series of tracks or rails mounted thereon forming a grid pattern above the stacks of containers, the containers being configured for occupying a footprint of one grid space of the tracks or rails, the tracks or rails having operable thereon at least one robotic load handling device configured and arranged so as to lift and retain one container and transport said container to a predetermined output port of the storage system.

6. A nested container configured and adapted for use in combination with the parcel sorting system of claim 1.

7. A nested container comprising: a rigid outer container and an inner flexible container, the inner container having deployable fixing means configured for enabling conformation of outer surfaces of the inner flexible container with inner surfaces of the outer rigid container.

8. A parcel sorting system as claimed in claim 4, comprising: a grid-based storage system arranged so as to store said containers in stacks within a framework, the framework having a series of tracks or rails mounted thereon forming a grid pattern above the stacks of containers, the containers being configured for occupying a footprint of one grid space of the tracks or rails, the tracks or rails having operable thereon at least one robotic load handling device configured and arranged so as to lift and retain one container and transport said container to a predetermined output port of the storage system.

9. A nested container configured and adapted for use in combination with the parcel sorting system of claim 4.

Description

[0025] The invention will now be described with reference to the accompanying drawings in which:

[0026] FIG. 1 shows a schematic, side view of one form of sorting system for parcels and packages in accordance with the invention, the system comprising a collapsible parcel holder locatable in a container formed from substantially rigid materials;

[0027] FIG. 2 shows a schematic, perspective view of one part of the sorting system of FIG. 1, showing in more detail the collapsible parcel holder being located in the rigid container to form a nested parcel handling device;

[0028] FIG. 3 shows a schematic, perspective view of a further part of the sorting system of FIG. 1, showing in more detail parcels and packages of varying shapes and sizes being automatically deposited in the nested parcel handling device;

[0029] FIG. 4 shows a schematic, perspective view of a subsequent part of the sorting system of FIG. 1, showing a securing device in accordance with a further form of the invention, the securing device substantially securing the parcels and packages in the collapsible parcel holder to prevent parcels and packages from falling from the collapsible parcel holder whilst enabling the holder to be handled by further mechanical handling equipment;

[0030] FIG. 5 shows a perspective view of an alternative form of sealing mechanism for the collapsible parcel holder;

[0031] FIG. 6 shows a perspective view of one form of separating device for removing the collapsible parcel holder from the rigid container, the removed collapsible parcel holder comprising structural members enabling maximum packing density of parcels and packages within the parcel holder;

[0032] FIG. 7 shows a perspective view of the sealed parcel holder in accordance with one form of the invention being further transported through the parcel and package sorting system;

[0033] FIG. 8 shows a perspective view of a plurality of parcel holders together with a plurality of rigid shipping containers, the packing density of the parcel holders and rigid shipping containers being maximized;

[0034] FIG. 9 shows the parcel holders and shipping containers being loaded in to suitable transportation vehicles, the parcel holders retaining structural integrity so as to enable maximum packing efficiency; and

[0035] FIG. 10 shows an alternative form of the depositing part of the sorting system of FIG. 3 in accordance with the invention, showing in more detail parcels and packages of varying shapes and sizes being automatically deposited in the nested parcel handling device.

[0036] As shown in FIG. 1, the sorting system comprises a number of discrete parts, a presentation portion 1, a filling portion 2, a securing and sealing portion 3, a separating portion 4 and an onward transportation portion 5

[0037] The presentation portion 1 comprises means for presenting a flexible, collapsible parcel holder 6 in to more structurally rigid container 7 so as to create a composite container 8. It will be appreciated that there are many ways of presenting a flexible bag and locating it in a more rigid container. However, in the present invention, once presented to the structurally rigid container 7, the flexible parcel holder or bag 6 is held in an open position within the container 7 by a deployable and releasable mechanism.

[0038] This mechanism may take the form of Velcro strips around the open circumference of the bag 6 or flexible parcel holder 6. It will be appreciated that the Velcro hook strips around the top of the bag or flexible parcel holder 6 co-operate with opposing loop strips fixedly attached to the top, open, inner surface of the rigid container 7.

[0039] The deployable mechanism may further take the form of collapsible semi-rigid and resilient strips fixedly attached to the top and edges of the flexible parcel holder or bag 6 such that when the flexible parcel holder or bag 6 is placed in the container 7, the strips deploy in a more rigid format such that the flexile parcel holder takes the form of the container 7. For example, shape memory materials may be used that can be activated between a flexible, collapsible form and a more structurally rigid form.

[0040] It will be appreciated that the flexible parcel holder will need to be maintained in an open position and as such a form of male retaining and engaging portion (not shown) may be provided in the structure of the container 7 that co-operates with a releasable female portion formed in the flexible parcel holder or bag. It will be appreciated that this is only one way in which the flexible collapsible parcel holder or bag may be retained in an open yet nested manner within the container 7. Any other form of releasably cooperating mechanism may be used.

[0041] In order to ensure that the flexible bag or parcel holder 6 is fully inserted in to the container 7, and taking the shape of the container 7, the presentation portion may comprise pushing or inserting means (not shown, but direction of movement indicated by the downward arrow in FIG. 2).

[0042] On exiting the presentation portion 1, the flexible parcel holder or bag 6 is fully located in the container 7 to form a nested entity 8.

[0043] The nested entity 8, hereinafter the nested container 8, is routed to the filling portion 3. At the filling portion 3, parcels, or packages, or shipment containers 10 and all other items suitably wrapped for onward transportation to a desired location are directed in to the nested container 8.

[0044] It will be appreciated that the parcels and packages 10 put in the nested container 8 may comprise items for transportation to the same destination, or for the same customer or for onward transportation to another part of the sorting and shipping system.

[0045] It will be further appreciated that the parcels and packages 10 put in to the nested container 8 may be manually placed therein or robotically placed therein or placed therein by any other suitable automated or manual process. Furthermore, the filling portion 2 may comprise part of a larger parcel sorting system such as that described in PCT Patent Publication Number WO2015/197696 (Ocado Innovation Limited) published on 30 Dec. 2015, the contents of which are hereby incorporated by reference.

[0046] FIG. 10 shows an alternative form of filling portion 2 in which the parcels and packages 10 to be placed in to the nested container 8 are passed through a resilient chute, the resilient nature of the chute 12 acting so as to slow the descent of the parcels and packages in to the nested container 8 so as to prevent damage. It will be appreciated that this may allow parcels and packages to be dropped from greater heights or from different levels in the same building or warehouse system.

[0047] Once the nested container 8 is filled to a required or predetermined level, that may be defined by the density of packing of parcels within the flexible parcel holder 6, the filled nested container 8 is transported by suitable conveyance means to the sealing and securing portion 3.

[0048] The securing and sealing portion 3 comprises means for preventing the contents of the flexible parcel holder 6 from falling out once the holder 6 is removed from the container 7. Furthermore, the mechanism comprising the sealing and securing portion has the advantage of imparting some structural resilience to the flexible parcel holder 6 such that it may be stacked or stored in a space efficient manner even once removed from the container 7.

[0049] One form of sealing and securing portion 3 is shown in FIG. 4. It will be appreciated that this is one form only of such a mechanism and any other mechanism may be used that acts so as to seal and secure the parcels and packages within the flexible parcel holder 6.

[0050] FIG. 4 shows a nested container 8 comprising packages and parcels entering the mechanism. The flexible parcel holder 6 comprising the parcels further comprises 4 handles located at the corners of the top of the parcel holder 6. The mechanism comprises means for grabbing said handles and releasing the flexible parcel holder 6 from the container 7. In the example shown in FIG. 4, the mechanism will lift the parcel holder 6 in an upward direction. Whilst the parcel holder 6 is being lifted out of the container 7, a sealing mechanism acts so as to place a lid portion on the flexible parcel holder 6. In the mechanism shown in FIG. 4, in order to assist in the sealing and securing of the flexible parcel holder or bag 6 within the container 7, the mechanism may rotate the arrangement so the weight of the parcels and packages within the bag 6 in the container 7 assists in the sealing and securing of the lid portion on the flexible parcel holder 6. It will be appreciated that the rotation of the arrangement only occurs once the lid portion is sufficiently in contact with the flexible parcel holder or bag 6.

[0051] FIG. 5 shows an alternative mechanism for sealing and securing the flexible parcel holder 6. In this form of the invention the flexible parcel holder or bag 6 comprises cable means that act in a drawstring manner so as to close the top of the parcel holder or bag 6. This may be achieved via any known method to a person skilled in the art. However, it may be achieved by locating a tie or cable in a seam in the circumference of the open flexible bag 6. A portion of the cable or tie may protrude from the seam such that it may be pulled by any suitable hook mechanism and act so as to close the top of the bag 6. It will further be appreciated that the handles of the flexible parcel sorter or bag 6 maybe used and drawn together and tied by cable tie means in an automated or manual system. It will be noted that in this mechanism additional space may be required at the top of the flexible parcel holder or bag 6 to allow for a drawstring effect.

[0052] Once the flexible parcel holder or bag 6 is sealed and secured by any suitable mechanism or method the nested container 8 is conveyed by suitable conveyance means to the separating portion 4.

[0053] The separating portion 4 comprises any suitable means of lifting the flexible parcel holder or bag 6 from the container 7. In the example shown in FIG. 6 a gantry crane is used to releasably attach to the handles of the flexible parcel holder 6 and separate the parcel holder 6 from the nested container 8.

[0054] Once the parcel holder or bag 6 is removed the empty rigid container 7 can be returned to the presentation portion 1 and receive a further parcel holder 6 or bag for filling with parcels and packages as required.

[0055] The separated semi rigid flexible parcel holder 6 may now be transported by any suitable conveyance means to the transportation portion 5 where a semi-rigid structure of the flexible parcel holder or bag 6 is achieved as the parcels and packages therein were located in the holder or bag 6 when supported by the container 7.

[0056] It will be appreciated that the lid portion provides further structural support to the parcel holder or bag 6. It will further be appreciated that the lid portion may comprise suitable fastening means for attaching the lid portion to the flexible parcel holder or bag 6. This may comprise hook and loop fastening as previously described above.

[0057] It will be further appreciated that once the removed parcel holder or bag 6 comprises a semi rigid form aided by the parcels and packages therein, it is possible to transport said holder or bag 6 as a separate entity. This may include stacking a plurality of said holders or bags 6 together or in association with other packages and containers such as depicted in FIG. 8. Furthermore, as shown in FIG. 9, said stacks of mixed containers and bags 6 or bags 6 only may be moved via crane or other winching device and located in a suitable transporting vehicle. It will be appreciated that the stacked nature of the semi rigid bags 6 and other containers assists in achieving improved packing density of containers and bags in said vehicle.

[0058] In one form of the invention, when the nested container 8 comprises parcels and packages, it may be conveyed by suitable conveyance means to a temporary storage portion of the sorting system. This may be required if adequate fill of the nested container 8 has not yet been achieved, in which case the flexible parcel holder or bag 6 may be in an open format or if there is a delay before a fully filled nested container 8 can be shipped via appropriate means, in which case the flexible parcel holder or bag 6 may be sealed and secured.

[0059] In either case, the location of the flexible parcel holder or bag 6 in a rigid container 7 allows for known storage systems to be used for temporary storage of the nested containers 8.

[0060] Such temporary storage systems may comprise grid-based systems such as those disclosed in EP(UK) 3030504 published as WO2015/019055A1 on 12 Feb. 2015, the content of which is hereby incorporated by reference.

[0061] It is an advantage of the parcel sorting system described above that the rigid structural containers 7 may form the containers described in the publication described above.

[0062] In all of the embodiments described above, the nested container 8 or the rigid container 7 or the semi-rigid flexible parcel holder or bag 6 may be conveyed between portions of the system or temporary locations by any suitable conveyance means. Indeed rigid containers 7 or nested containers 8 may be conveyed via robotic load handling devices as described in WO2015/019055 as incorporated by reference. However, it will be appreciated that this need not be the case and any suitable form of conveyor such as roller conveyor, powered or otherwise, may be used.

[0063] Whilst the description above relates to a system for shipping packages and parcels it will be appreciated that it may form part of a general merchandise system or any other retail system requiring goods to be shipped in parcels to discrete geographical locations. This may include but not be limited to online retail systems.

[0064] It will further be appreciated that the various portions described above may be as shown in the appended Figures or any suitable mechanisms capable of fulfilling the functions described may be used.