CONTAINER PALLET, MODULE AND RACK AND RELATED METHODS

Abstract

A container pallet (10) is provided which includes a lattice of walled cells (12) for supporting a plurality of tessellatable containers in a close packed arrangement. Each walled cell (12) has a profile of a polygon that is tessellatable with itself or one or more other polygons and each walled cell (12) comprises a lower side wall (16). An upper side wall (14) may be provided in each walled cell and inset from the lower side wall, and/or a retaining lip may be provided around some or all of the periphery the container pallet. The container pallet may be modular.

Claims

1-27. (canceled)

28. A container pallet or battery cell framework comprising a lattice of walled cells for receiving and/or supporting a plurality of tessellatable containers in a close packed arrangement where side walls of the containers contact each other, in which each walled cell has a profile of or approximating a polygon that is tessellatable with itself or one or more other polygons, and one of: each walled cell includes a lower side wall and an upper side wall, and the upper side wall is inset from the lower side wall in a direction towards a central axis of the walled cell; or each walled cell includes a container receiving surface and a lower side wall extending away from the container receiving surface, each walled cell having a central axis, and at least one retaining lip is provided around a periphery of the container pallet or battery cell framework.

29. A container pallet or battery cell framework as claimed in claim 28, in which the upper side wall is angled inwards towards the central axis.

30. A container pallet or battery cell framework as claimed in claim 28, in which the walled cells are arranged in a horizontal plane.

31. A container pallet or battery cell framework as claimed in claim 28, in which the lower side wall and where provided the upper side wall define an aperture through the walled cell.

32. A container pallet or battery cell framework as claimed in claim 28, in which the lower side wall of at least some of the walled cells include engagement elements for engagement to one or more container pallets or battery cell frameworks and/or to one or more container pallet modules or battery cell framework modules.

33. A container pallet or battery cell framework as claimed in claim 28, comprising one or more sensors for sensing a weight of one or more of the containers above the one or more sensors.

34. A container storage system or battery comprising: a rack for a plurality of containers in a tessellated or pseudo-tessellated arrangement, the rack comprising a base, a first side wall extending from the base, a second side wall extending from the base, the second side wall opposing the first side wall, a front, and a rear opposing the front, in which the first side wall includes a first corrugated face opposing the second side wall, and/or the second side wall includes a second corrugated face opposing the first side wall, and the base includes a base face extending between the first and second side walls from at or adjacent to the first and/or second corrugated faces, in which the base face and the or each corrugated face together define a surface profile for conforming to at least some sides of the tessellated or pseudo-tessellated arrangement of containers, in which a cross-section of the surface profile remains substantially identical or constant in a direction extending from the front to the rear of the rack for conforming to the arrangement of containers, and one of: a) a plurality of containers disposed in the rack in a tessellated or pseudo-tessellated arrangement, each container being removable from the rack independently of other containers; b) a plurality of containers disposed in the rack in a tessellated or pseudo-tessellated arrangement, and first and/or second container pallets or battery cell frameworks each as claimed in claim 1 at the front and/or rear of the rack respectively; and c) a plurality of containers disposed in the rack in a tessellated or pseudo-tessellated arrangement, and first and/or second container pallets or battery cell frameworks at the front and/or rear of the rack respectively, each of the first and/or second container pallets or battery cell frameworks being a modular container pallet or modular battery cell framework for receiving and/or supporting the plurality of containers in a close packed arrangement where side walls of the containers contact each other, comprising a plurality of container pallet modules or battery cell framework modules, connected together in a tessellated arrangement or lattice, each container pallet module or battery cell framework module comprising: a walled cell having a profile of or approximating a polygon that is tessellatable with itself or one or more other polygons, the walled cell including a lower side wall and upper side wall, in which the upper side wall is inset from the lower side wall in a direction towards a central axis of the walled cell, and the module includes side wall connection means for allowing connection of the module to at least one additional module.

35. A method of using a container storage system or battery as claimed in claim 34, the method comprising at least one of: removing one or more of the containers from the rack; inserting one or more replacement containers into the rack or into vacancies in the rack; and displacing one of the plurality of tessellated or pseudo-tessellated containers from the rack by inserting a second container into the rack.

36. A container pallet module or battery cell framework module for tessellation and assembly with one or more other modules into a container pallet or battery cell framework, the module comprising a walled cell having a profile of or approximating a polygon that is tessellatable with itself or one or more other polygons, the walled cell including a lower side wall and upper side wall, in which the upper side wall is inset from the lower side wall in a direction towards a central axis of the walled cell, and the module includes side wall connection means for allowing connection of the module to at least one additional module.

37. A container pallet module or battery cell framework module as claimed in claim 36, in which the lower side wall and upper side wall together define an aperture through the walled cell.

38. A container pallet module or battery cell framework module as claimed in claim 36, in which a foot or a plurality of feet extend downwards from the lower side wall for supporting the lower side wall in a raised position spaced from an adjacent wall or ground.

39. A container pallet module or battery cell framework module as claimed in claim 36, in which the side wall connection means includes engagement elements on the lower side wall for engagement to one or more container pallet modules or battery cell framework modules and/or to one or more container pallets or battery cell frameworks.

40. A container pallet module or battery cell framework module as claimed in claim 39, in which the engagement elements include protrusions and/or recesses arranged along the lower side wall in a direction parallel to the central axis.

41. A modular container pallet or modular battery cell framework for receiving and/or supporting a plurality of tessellatable containers in a close packed arrangement where side walls of the containers contact each other, comprising a plurality of container pallet modules or battery cell framework modules each as claimed in claim 36, connected together in a tessellated arrangement or lattice.

42. A method of assembling a container pallet or battery cell framework for a plurality of tessellated containers, the steps comprising: providing a plurality of container pallet modules or battery cell framework modules as claimed in claim 3; and connecting or securing the modules together.

43. A rack for a plurality of containers in a tessellated or pseudo-tessellated arrangement, comprising a base, a first side wall extending from the base, a second side wall extending from the base, the second side wall opposing the first side wall, a front, and a rear opposing the front, in which the first side wall includes a first corrugated face opposing the second side wall, and/or the second side wall includes a second corrugated face opposing the first side wall, and the base includes a base face extending between the first and second side walls from at or adjacent to the first and/or second corrugated faces, in which the base face and each corrugated face together define a surface profile for conforming to at least some sides of the tessellated or pseudo-tessellated arrangement of containers, in which a cross-section of the surface profile remains substantially identical or constant in a direction extending from the front to the rear of the rack for conforming to the arrangement of containers.

44. A rack as claimed in claim 43, comprising one or both of: the base face is a corrugated face; and each corrugated face includes one or more elongate grooves and/or elongate protrusions for complementing corresponding portions on sides of the containers.

45. A rack as claimed in claim 43, including a plurality of container sleeves for each receiving one of the plurality of containers, and at least one of: the container sleeves being provided in a tessellated arrangement or lattice in the rack; and lubricant is provided on one or more internal surfaces of one or more of the container sleeves for facilitating ingress and/or egress of a container.

46. A method of packing or securing a plurality of tessellatable containers using at least two container pallets or battery cell frameworks, each container pallet or battery cell framework including a lattice of cells arranged in a plane, the method comprising the steps of: locating a bottom end of each container in the plurality of containers to a topside of a respective cell of a first container pallet or battery cell framework; and locating undersides of cells of a second container pallet or battery cell framework to respective top ends of the plurality of containers, to sandwich the plurality of containers between the container pallets or battery cell frameworks.

47. A method as claimed in claim 46, further comprising packing or securing a second plurality of containers using a third container pallet or battery cell framework which has a lattice of cells arranged in a plane, including the steps of: locating a bottom end of each container of the second plurality of containers to a topside of a respective cell of the second container pallet or battery cell framework; and locating undersides of cells of the third container pallet or battery cell framework to respective top ends of each of the second plurality of containers, to sandwich the second plurality of containers between the second and third container pallets or battery cell frameworks.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0176] For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the accompanying drawings, in which:

[0177] FIG. 1 shows a perspective view of a first embodiment of a container pallet or battery cell framework;

[0178] FIG. 2 shows perspective views of a container positioned between two pallets or frameworks of FIG. 1;

[0179] FIG. 3 shows a top perspective view of a plurality of containers in a close-packed arrangement between two pallets or frameworks of FIG. 1;

[0180] FIG. 4 shows a side view of the containers and pallets/frameworks of FIG. 3, with a second layer of containers and a second pallet/framework;

[0181] FIG. 5a shows a perspective view of a second embodiment of a container pallet or battery cell framework, including a peripheral lip and an exemplary container;

[0182] FIG. 5b shows a perspective view of a plurality of containers in a close-packed arrangement between two pallets or frameworks of FIG. 5a;

[0183] FIG. 6 shows first and second perspective views of a container pallet module or battery cell framework module;

[0184] FIG. 7 shows perspective views of a plurality of modules of FIG. 6 being connected together into a modular container pallet or modular battery cell framework;

[0185] FIG. 8 shows perspective views of first and second types of foot or support/spacer element for a container pallet or battery cell framework;

[0186] FIG. 9a shows top and base perspective views of the feet of FIG. 8 connected to the module of FIG. 5a;

[0187] FIG. 9b shows base perspective views of a third type of foot or support/spacer element being connected to the module of FIG. 5a;

[0188] FIG. 10 shows a perspective view of a plurality of feet of FIG. 8 connected to the modular pallet or framework of FIG. 7;

[0189] FIG. 11 shows a perspective view of a first embodiment of a rack;

[0190] FIG. 12 shows a perspective view of a second embodiment of a rack;

[0191] FIG. 13a shows a perspective view of a plurality of containers between modular pallets/frameworks of FIG. 7 being loaded into the rack of FIG. 12;

[0192] FIG. 13b shows a front view of the rack of FIG. 13a, with the containers in situ;

[0193] FIG. 14 shows perspective views of a container insertable into a container sleeve;

[0194] FIG. 15 shows a perspective view of a plurality of container sleeves and containers of FIG. 14, provided in the rack of FIG. 11;

[0195] FIG. 16 shows a cross-sectional perspective view of a second embodiment of a container sleeve, and two containers therein; and

[0196] FIG. 17 shows a perspective view of a plurality of container sleeves and containers of FIG. 16, provided in another embodiment of a rack.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0197] Referring firstly to FIG. 1, a first embodiment of a container pallet (or a battery cell framework) for a plurality of tessellated containers is generally shown at 10. It is shown in an upright orientation which may be a floor-standing configuration, and subsequent references to upper and lower should be construed when considering FIG. 1 and accompanying text in the normal orientation of that page. However, in the case of a battery cell framework, it will be appreciated that a battery including the framework may be provided in any suitable orientation for powering a device.

[0198] The container pallet 10 comprises a plurality of cells 12. Whilst eighteen cells are provided in this embodiment, it will be appreciated that the pallet 10 may be provided with any number of cells (although preferably the cells are arranged to minimise the perimeter length of the pallet as a whole).

[0199] The cells 12 are arranged in a horizontal plane. Each cell 12 has a regular hexagonal profile. Each cell 12 is substantially identical in this embodiment. Each cell 12 is tessellated with adjacent cells 12 to form a honeycomb-type structure.

[0200] The term tessellation is used in this description to mean a regular packing arrangement which results in a repeated array of the same shape, or complementary shapes, in a plane. The term tessellation does not necessarily imply an absence of interstices between tessellated elements.

[0201] Each cell 12 has an upper side wall 14 and a lower side wall 16. The upper side wall 14 extends in a direction above the horizontal plane. The lower side wall 16 extends in a direction below the horizontal plane. The upper side wall 14 extends in a direction substantially parallel to the lower side wall 16. The upper side wall 14 is inset from the lower side wall 16. The upper side wall 14 is inset from the lower side wall 16 by a container receiving surface (or lateral wall) 18. The container receiving surface 18 extends from a bottom of an exterior of the upper side wall 14 to a top of the exterior of the lower side wall 16. The container receiving surface 18 extends in a direction perpendicular to the lower side wall 16. Each cell 12 is sized and shaped to receive a single container 500 during use.

[0202] As described above, the cells 12 are tessellated to form a honeycomb structure, and the lower side walls 16 of adjacent cells 12 form a single structure in this embodiment.

[0203] The container receiving surfaces 18 provide spaces between the upper side walls 14 of adjacent cells 12.

[0204] In each cell 12, the upper side wall 14 and lower side wall 16 define a through aperture 20. The cell aperture 20 forms a majority of the cross-section of the cell 12. Near edges of apertures 20 of adjacent cells are spaced apart by the thicknesses of the side walls between them.

[0205] For each cell in this embodiment, the upper side wall 14 has a substantially hexagonal profile. The lower side wall 16 has a substantially hexagonal profile. The hexagonal profile of the lower side wall 16 has a greater cross-sectional area than the hexagonal profile of the upper side wall 14. The upper and lower side walls 14, 16, have concentric hexagonal profiles, i.e. they share a common centre.

[0206] The lower side wall 16 includes a plurality of engagement elements on its side faces.

[0207] In this embodiment, each face has a single engagement element but it will be appreciated that any suitable number of engagement elements may be provided per face in other embodiments. This includes multiple engagement elements per face and different numbers of engagement elements per face, including not providing engagement elements on every side face.

[0208] The engagement elements include three protrusions 26 and three recesses 28. The three protrusions 26 are provided on respective consecutive sides of each lower side wall as seen in FIG. 1. The three recesses 28 are provided on the other three respective consecutive sides of each lower side wall. It will be appreciated that inner sides of the lower side walls can be seen through the apertures 20, and that protrusions on those inner sides correspond to recesses 28 in the outer sides of the lower side walls. However, it is not essential for the recesses in the exterior of the lower side wall to have corresponding inner protrusions. The engagement elements are discussed in more detail below.

[0209] Each upper side wall 14 includes a plurality of recesses 30. In this embodiment, there are six recesses 30 per upper side wall. The recesses 30 in this embodiment are located at the corners of the hexagonal profile. Each recess 30 has a curved or arcuate profile. Each recess 30 extends from the lateral container receiving surface to the top of the upper side wall.

[0210] It will be appreciated that any suitable number of recesses 30 may be provided per upper wall. The number of recesses may be the same as or different from (higher or lower) the number of sides of the polygonal profile. Whilst the recesses 30 are in the corners here, the recesses may alternatively or additionally be provided partway along the exterior faces of the upper side wall.

[0211] Referring also to FIG. 2, the structure of each cell 10 is tailored to receive a tessellatable container 500. The tessellatable container has the form of a hexagonal prism with six major external side faces. Examples of suitable containers are described in GB2573330, GB2573356 and GB2581814. The container 500 has a top end 502 and a bottom end 504. The container 500 has a medial portion 506 between the top end 502 and bottom end 504. The upper side wall 14 of a first container pallet 10 is configured to fit the bottom end 504 of the container 500. The lower side wall 16 of a second container pallet 10 is configured to fit the top end 502 of the container 500.

[0212] The bottom end 504 of the container has a height substantially similar to the height of the upper side wall 14. The upper side wall 14 can be considered as a container engagement profile. The bottom end 504 has a complementary engagement profile for receiving the upper side wall 14. During use, the upper side wall 14 is flush with the bottom end 504 of the container 500. The upper sidewall 14 inhibits movement of the container 500 in a direction parallel to the horizontal plane of the container pallet 10.

[0213] That is, it inhibits lateral movement of the container 500.

[0214] The medial portion 506 has a profile substantially identical to the profile of the lower side wall 16. When the upper side wall 14 is flush with the bottom end 504 of the container 500, the lower side wall 16 is disposed substantially in the vertical plane of the external faces of the medial portion 506.

[0215] The top end 502 has a height substantially similar to the height of the lower side wall 16. The lower side wall 16 can be considered as a container engagement profile. The top end 502 has a complementary engagement profile for being received by the lower side wall 16 of the second container pallet. During use, the top end 502 is flush with that lower side wall 16. Like the upper sidewall of the first pallet, the lower sidewall 16 of the second pallet inhibits movement of the container 500 in a direction parallel to the horizontal plane of the container pallet 10.

[0216] The top end 502 is indented from the medial portion 506 of the container 500. The indentation is in a radially inwards direction relative to the six major sides of the container. The indentation of the top end 502 is substantially the same distance as the width of lower side walls 16 of the container pallet 10.

[0217] For each container in this embodiment, each external face of the container 500 has either a protrusion 508 or a recess 510. The recess 510 is sized and shaped like an opposite of the protrusion 508, so they can fit together in a complementary manner.

[0218] The protrusions 508 and recesses 510 each extend along a length of the medial portion 506 (i.e. between the top end 502 and bottom end 504).

[0219] To provide the containers 500 tessellated side-by-side in a plane, each container may be located to one of the cells 12, in orientations where one container in a given pair of adjacent containers has a protrusion 508 and the other container in the pair has a corresponding recess 510. In this embodiment, the container pallet 10 is arranged to receive containers 500 which have recesses 510 and protrusions 508.

[0220] In other embodiments, at least part of the medial portion 506 may be substantially free of protrusions 508 and recesses 510 as disclosed in GB2581814.

[0221] The top end 502 features protrusions 503 and recesses 505 which correspond to the protrusions 26 and recesses 28 in the lower side wall 16.

[0222] The container pallet 10 can tesselate with adjacent container pallets 10 in the same manner as the containers 500 themselves, via the corresponding engagement elements.

[0223] As can be seen in FIGS. 3 and 4, the containers 500 can be retained in the container pallet 10 in a close-packed arrangement. Single use packing materials, such as clingwrap, are not required to secure the containers. In this particular case, a second container pallet is shown on top of the layer of containers, but the second pallet is not essential if a single layer of containers is being stored, for example.

[0224] Multiple layers of container pallets 10 and containers 500 may be stacked on top of each other in the manner described above to form a layered structure 600, e.g. two layers of containers as shown in FIG. 4. The protrusions 508 and recesses 510 along the length of the containers 500 and the corresponding protrusions 26 and recesses 28 of the lower side walls 16 of the container pallets 10 can be considered to form a single protrusion or recess on each face of the layered structure 600. The layered structure 600 can tessellate with adjacent layered structures 600 in a manner similar to the container 500 and container pallet 10.

[0225] The dashed line 29 in FIG. 4 shows how, in other embodiments, the upper side wall 14 may extend in a direction angled towards a centre of the cell. That is, how the upper side wall of each pallet cell may be angled inwards. The angle between the horizontal plane and the upper side wall 14 may be between 70 and 90.

[0226] FIGS. 5a and 5b show a second embodiment of the container pallet, generally indicated at 10, with an exemplary container 500 in situ on the pallet. The container pallet 10 is substantially similar to the container pallet 10 described in the first embodiment unless stated otherwise. Where possible, like reference numerals are used to like features relative to the first embodiment.

[0227] In this embodiment, upper side walls 14 are not included in each cell 12. It will be understood that some or all of the cells 12 may possess upper side walls 14 in other embodiments.

[0228] The container pallet 10 has a periphery 40. The periphery 40 is formed from faces of the lower side walls 16 which are not directly adjacent to and facing another cell 12.

[0229] In other words, the periphery 40 is defined by sides of the outermost cells.

[0230] In this embodiment, a lip 42 or peripheral wall is provided around a periphery 40 of the container pallet 10. The lip 42 prevents the containers 500 from sliding sideways out of the container pallet 10. The lip 42 extends above and below the horizontal plane of the container pallet 10. The lip 42 extends in a direction substantially perpendicular to the horizontal plane of the container pallet 10.

[0231] Containers 500 can be loaded onto the pallet 10 by locating a first container to a cell such that it fits neatly against the lip 42, and then loading additional containers such that they fit to that container and where applicable another portion of the lip 42. The orientations of the containers should again be such that, in a given pair of adjacent containers, one container has a protrusion 508 and the other container in the pair has a corresponding recess 510 facing it.

[0232] It will be appreciated that the peripheral lip in this embodiment extends around the full periphery of the pallet 10, but that in other embodiments the lip may extend only partway around the periphery or may be an interrupted lip (e.g. with a plurality of lip walls spaced apart around the periphery).

[0233] During use, when containers are provided on the pallet 10, the lip 42 extends above the plane of the container pallet 10 to a height just above the bottom end 504 of a container 500 disposed on the container pallet 10. The bottom end 504 of the container 500 may be substantially flush with the height of the lip 42 during use.

[0234] FIG. 5b shows a plurality of containers 500 sandwiched between two container pallets 10. During use, the lip 42 extends below the horizontal plane of the upper container pallet 10 to a height just below the top end 502 of a container 500 disposed below that container pallet 10. The top end 502 of the container 500 may be substantially flush with the lip 42 during use.

[0235] When viewed from above, the lips 42 of each container pallet 10 lie proud of the side faces of each container 500, unlike the pallet of the first embodiment.

[0236] In this embodiment, lateral movement of the individual containers 500 is prevented by the tessellation of the containers and the lip 42.

[0237] Referring now to FIGS. 6 to 7, a third embodiment of the container pallet of battery cell framework is indicated generally at 10. Where possible, like reference numerals are used to like features relative to the first embodiment. In some ways, the features of the container pallet 10 are substantially similar to that of the first embodiment. However, in this embodiment each cell 12 is provided by an individual container pallet module or battery framework module 11, shown in FIG. 6.

[0238] In this embodiment, a lower side wall 16 of the cell of the module 11 has module-to-module connection means. In this embodiment, there are six connection means corresponding to the six faces of the hexagonal module (although any suitable number of connection means may be provided in other embodiments). It will be appreciated that other embodiments of the module 11 may have other polygonal profiles as discussed generally above.

[0239] In this embodiment, the connection means include apertures 50 through each major face of the polygonal profile, i.e. through each of the six main sides of the lower side wall 16. The connection means is disposed on each face of the lower side wall 16.

[0240] The connection means provides a way to adjacent cells 12 together. The apertures 50 are disposed through the centre of each face of the lower side wall 16. The apertures 50 are disposed through part of (or a centre of) each of the protrusions 26 and recesses 28. The apertures 50 can receive screws 52 or other fixing means which are used to connect the modules 11 together (e.g. using corresponding nuts and optionally washers), as shown in FIG. 7. The screw apertures 50 and screws 52 allow the modules 11 to be releasably secured to each other.

[0241] The connection means also include the engagement elements (protrusions 26 and recesses 28) which are slotted together or mutually engaged to line up pairs of the apertures 50 on separate modules 11 to be secured together.

[0242] In the six main interior corners of the lower side wall 16, corresponding to corners of the hexagonal profile, circular or curved recesses 31 are provided. These are not essential but may be provided in some or all of the cells of any other embodiment.

[0243] Multiple modules 11 can be connected to form a container pallet 10 similar to that of the first and second embodiments. However, due to the modular nature of the cells 12 in this embodiment, the number and arrangement of cells 12 in the container pallet 10 can be fully customised.

[0244] In this embodiment, the upper side wall 14 extends in a direction angled towards a centre of the aperture 20, i.e. it is slanted inwards. The angle between the horizontal plane and the upper side wall 14 is between 70 and 90.

[0245] Referring now to FIG. 8, two container pallet feet are indicated generally at 60a and 60b. The first type of foot 60a has a recess for corresponding to or continuing a recess in the pallet or module in earlier embodiments. The second type of foot 60b has a protrusion for corresponding to or continuing a protrusion in the pallet or module in earlier embodiments.

[0246] The container pallet feet 60a, 60b may be used to raise the container pallet 10, relative to the ground to provide a gap for the tines of a forklift. If used in a battery cell framework, the feet may be considered to be spacer elements or supporting elements. Each type of foot 60a, 60b includes a substantially rectangular body 61a, 61b. A pallet connection portion 62a, 62b extends from each rectangular body 61a, 61b. In this embodiment, the connection portions are comparatively thinner than the bodies 61a, 61b. The container pallet feet 60a, 60b can be received by the lower side wall 16 of a pallet or module as described below.

[0247] The first type of foot 60a has an elongate recess 68. The recess 68 corresponds to one of the recesses 28 in the lower side walls 16 of the pallet cell 12. In other words, when the foot 60a is received by the lower side wall 16 of the cell 12, the foot 60a forms an extension of the recess 28 in the lower side wall 16.

[0248] The second type of foot 60b has an elongate protrusion 70. The container pallet foot protrusion 70 corresponds to one of the protrusions 26 in the lower side wall 16 of a pallet cell 12. In other words, when the foot 60b is received by the lower side wall 16 of the cell 12, the foot 60b forms an extension of the protrusion 26 in the lower side wall 16.

[0249] The pallet connection portions 62a, 62b are each receivable by the container pallet 10 during use. Each pallet connection portion 62a, 62b is inset from the recessed/protruding side of the rectangular body 61a, 61b. The offset provides a lower side wall receiving face 63a, 63b for seating against an interior face of the cell 12.

[0250] The pallet connection portion 62a of the foot 60a has a second recess 72. The second recess 72 is disposed in the middle of the connection portion 62a. The recess 72 corresponds to the cell recess 28 in the lower side wall 16 which receives the connection portion 62a, as shown in FIG. 9a.

[0251] The pallet connection portion 62b of the foot 60b has a second protrusion 74. The protrusion 74 is disposed in the middle of the connection portion 62b. The protrusion 74 corresponds to the cell protrusion 26 in the lower side wall 16 which receives the connection portion 62b, as shown in FIG. 9a.

[0252] The pallet connection portions 62a, 62b include apertures 76a, 76b through the pallet connection recess 72 and pallet connection protrusion 74 respectively, so that they can be secured using the same screws or bolts used to interconnect the modules 11, for example. For the non-modular pallets, lateral apertures may still be provided through some or all of the lower side walls in order to facilitate securing feet thereto. The container pallet feet 60a, 60b can be attached to the container pallet as shown in FIGS. 9a, 9b and 10, using fixing means such as screws (not shown). In FIG. 9a, the container pallet feet 60a, 60b correspond to a single side of the lower side wall 16. However, the two container pallet feet 60a, 60b may be provided as a single piece, generally indicated at 60c in FIG. 9b, where the foot 60c has two portions angled with respect to each other by an internal angle of the hexagonal (or other) profile of the cell. This may provide more stability for the pallet, e.g. at corners of a pallet.

[0253] While the feet are depicted as attached to the modular pallet of the third embodiment, it will be appreciated that the container pallet feet 60a, 60b can be connected to the cells 12, 12 of the first or second embodiments where a suitable connection means is provided.

[0254] Referring now to FIG. 11, a first embodiment of a rack for receiving or holding a plurality of tessellated containers 500 on their side is indicated generally at 100. The rack may be provided in a warehouse or other storage environment.

[0255] The rack 100 has a base 102. The rack has a first side wall 104. The rack 100 has a second side wall 106. The rack 100 is approximately U-shaped in profile. The rack is open at a front side 107. The rack is open at a rear side 109.

[0256] Boundaries between the base 102 and side walls 104, 106 are shown by the dashed lines.

[0257] The first side wall 104 extends from a first end 108 of the base wall 102. The first side wall 104 extends in a direction substantially perpendicular to the base wall 102. The second side wall 106 extends from a second end 110 of the base wall 102. The second side wall 106 extends in a direction substantially perpendicular to the base wall 102, and substantially parallel to the first wall.

[0258] The base and side walls 102, 104, 106 together define a container receiving region 112. The container receiving region 112 extends from the front 107 to the rear 109.

[0259] The receiving region 112 can receive containers 500 and container pallets described above.

[0260] The base wall 102 has a corrugated base face 114. The first side wall has a first corrugated side face 116. The first corrugated side face 116 faces towards the second side wall 106. The second side wall 106 has a second corrugated side face 118. The second corrugated side face 118 faces the first side wall 104. The corrugated faces 114, 116, 118 define a corrugated surface profile 119. The surface profile 119 substantially conforms to the shapes of the containers 500 when they are disposed in the receiving region 112. A cross-section of the surface profile remains substantially constant the front to the rear of the rack.

[0261] The rack may have a depth corresponding to the end-to-end length of a container 500.

[0262] To put containers into the rack, the containers 500 are disposed in the receiving region 112 on their sides. In other words, the top end 502 of each container 500 faces towards the front 107 or rear 109 and the bottom end 504 faces towards the other of the front 107 and rear 109. The external sides of the outermost containers 500 abut the corrugated faces 114, 116, 118.

[0263] The corrugations enable the base 102 and side walls 104, 106 to receive the containers 500 in their tessellated arrangement. The corrugation of the base face 114 includes a layer of trapezoidal recesses 120 (or trough-shaped recesses) spaced apart by trapezoidal protrusions or intervening walls. In this embodiment, the layer of trapezoidal recesses 120 has three trapezoidal recesses 120 and three corresponding walls (two between pairs of adjacent troughs, and one at the far end by the second side wall), but it will be appreciated that any suitable number of corrugations may be provided.

[0264] In this embodiment, the trapezoidal recesses 120 are substantially identical to each other. The trapezoidal recesses 120 are aligned on a horizontal plane.

[0265] The corrugations of the first and second side walls 104, 106 comprise v-shaped recesses 122a, 122b. Each v-shaped recess 122ab fits about two external sides of the outermost containers 500 during use. Each v-shaped recess is directly adjacent to another v-shaped recess on the respective side wall 104, 106, to form the corrugated internal faces 116, 118.

[0266] In use, the layer of trapezoidal recesses 120 receives a first layer of the containers 500. The first layer may be considered to have three containers 500, where containers 500 in a layer must be aligned on a common horizontal plane, i.e. at the same height above the base.

[0267] A second layer of the containers 500 can be introduced at a height above the first layer of containers 500. Those containers 500 then lie on the trapezoidal protrusions. There are three containers 500 in the second layer. The containers 500 of the second layer of containers 500 tesselate with the containers 500 of the first layer of containers 500.

[0268] Subsequent layers of containers for this embodiment can include third, fourth, fifth and sixth layers. Each layer has three containers 500 aligned on a horizontal plane. This is best shown in FIG. 13b with respect to the second embodiment of the rack 100 described below.

[0269] In some embodiments of the rack, each v-shaped recess 122a of the first side face 116 is aligned with a plane of a peak between two v-shaped recesses 122b on the second side face 118. That is, the v-shaped recesses on the two side walls may be anti-aligned. In other embodiments, peaks between each v-shaped recess 122a of the first side face 166 may oppose peaks between corresponding v-shaped recesses 122b at equivalent levels on the second side face 118. That is, the v-shaped recesses on the two side walls may be in alignment.

[0270] In other words, the corrugations of the first and second side faces 116, 118 may be considered in phase or out of phase depending on whether the v-shaped recesses are centred on common planes or not.

[0271] The rack 100 depicted in FIG. 11 is sized to contain six columns of tessellated containers 500 where a column extends in a direction perpendicular to a layer. This is best shown in FIG. 13b with respect to the second embodiment of the rack 100.

[0272] In this embodiment, the rack 100 is modular. The first and second side walls 104, 106 are provided as independent pieces which are detachably connected to the base 102.

[0273] Additional side wall pieces may be attached to increase the height of the rack 100. In other embodiments, the rack 100 may be integrally formed, or the modules may be different heights and/or widths to those depicted.

[0274] Referring now to FIG. 12, a second embodiment of a rack is generally shown at 100.

[0275] The second embodiment is substantially similar to the first embodiment unless stated otherwise. Like reference numerals will be used to indicate like features.

[0276] In the second embodiment, the first, second and third inner faces 114, 116, 118 include engagement elements. The engagement elements are configured to engage with the complementary protrusions or recesses of the containers 500. The engagement elements include elongate recesses 124 and protrusions 126. The recesses 124 and protrusions 126 extend across the rack 200 from the rear face to the front face. The recesses 124 and protrusions 126 correspond to the recesses 506, 28 and protrusions 508, 26 in the containers 500 and container pallets 10 described above.

[0277] The exact arrangement of protrusions and recesses (i.e. which face of which corrugation has a recess or a protrusion) can be selected to facilitate engagement with a tessellated group of containers. For example, in this embodiment, the base corrugations only has recesses, whilst sides of the v-shaped side wall corrugations alternate between protrusions (for sides facing towards the base) and recesses (for sides facing away from the base).

[0278] Save for the protrusions 126 and recesses 124, the general surface profile 119 of the rack 100 is substantially identical to that of the first embodiment.

[0279] FIGS. 13a and 13b show a plurality of tessellated containers 500 in the rack 100.

[0280] The containers 500 are in a tessellated arrangement. In this embodiment, the plurality of containers 500 are enclosed by two modular container pallets 10 of the third embodiment at either end (but other embodiments of container pallet could also be used, e.g. the first embodiment of pallet 10).

[0281] FIG. 13b shows the surface profile 119 of the rack 100 conforming to the shape of the tessellated arrangement of containers 500. The rack 100 contains six layers 128 of three containers 500 each, where a first layer is outlined by dashed lines. The rack 100 contains six columns 130 of three containers 500, where a column is also outlined by a second series of dashed lines.

[0282] In other embodiments, the rack 100 may contain a different number of layers 128 and/or a different number of columns 130. The number of corrugations may be adjusted accordingly.

[0283] Referring to FIG. 14, one of the containers 500 is shown filling a container sleeve which indicated generally at 200. The sleeve is open at a proximal end 208 for allowing a container in and out. The sleeve is also open at a distal end 210 in this embodiment, although that is not essential. In this embodiment, the sleeve 200 has a length roughly equal to or slightly more than the length of the container 500.

[0284] The sleeve 200 has internal faces 202 corresponding to the container. The sleeve has an external profile 204 which can tesselate together with other container sleeves 200.

[0285] The external faces of the containers 500 abut the internal face 202 when disposed in the sleeve 200.

[0286] A lubricant 203 can provided on the internal faces 202. The lubricant facilitates insertion of the container 500 into the sleeve 200 (or removal from it). In this embodiment, the lubricant 203 can provided by a coating or a fluid.

[0287] The internal faces 202 have protrusions 212 and recesses 214 corresponding to those already described for the container 500 above. The protrusions 212 and recesses 214 extend along the length of the sleeve 200. The protrusions 512 of the sleeve 200 are received by the recesses 210 of the container 500. The recesses 514 of the sleeve 20 receive the protrusions 508 of the container 500. The container 500 can slide in and out of the sleeve 200 substantially unhindered.

[0288] Note that in other embodiments the internal faces 202 of the sleeve 200 may be substantially free of protrusions 212 and/or recesses 214.

[0289] Referring now to FIG. 15, the container sleeves 200 are shown stacked inside the first embodiment of the rack 100. The containers 500 are tessellatable but spaced slightly apart due to the container sleeves, so the containers may be considered to be pseudo-tessellated. The container sleeves are in a tessellated arrangement.

[0290] The containers 500 can be independently inserted into and removed from each sleeve 200 as described above. The sleeves allow containers lower down in the rack to be removed without jeopardizing the stability of the containers above.

[0291] Referring now to FIG. 16, a second embodiment of the container sleeve 200 is shown. The second embodiment is substantially similar to the first embodiment of sleeve, but this sleeve 200 has a length approximately twice that of the containers 500. Two containers 500 are shown inserted in the sleeve 200. This allows at least partial insertion of a container into the sleeve which already holds a container, allowing the second container to displace the first (either by physically abutting it or displacing it as air between the containers compresses as one container approaches the other).

[0292] FIG. 17 shows another embodiment of a rack 100. The rack 100 is substantially similar to that of the first rack embodiment except that the distance between the front 107 and rear 109 is longer, to correspond to the longer sleeves 200. In other words, the rack 100 has a distance between the front 107 and rear 109 about twice (or more) that of the length of the containers 500. The sleeves 200 are shown stacked inside the rack 100 and can be inserted/removed in a similar manner to that previously described. It will be appreciated again that the rack may be sized to receive any desired number of containers and corresponding sleeves.

[0293] It will be appreciated that whilst the above embodiments are primarily described in relation to container pallets and container racks, equivalent embodiments are envisaged where the containers are battery cells and the container pallets are battery cell frameworks for aligning and engaging those battery cells. The container racks may in those embodiments be considered to be part of a battery casing or sheath or other battery structure, for example. In view of the similar structures of the framework and rack to those already described, these embodiments have not been described again, but the skilled person will appreciate that the same disclosure applies. Suitable electrical connections may be provided as needed to enable electrical power supply by the cells in the framework(s) and/or rack.

[0294] The embodiments described above are provided by way of example only, and various changes and modifications will be apparent to persons skilled in the art without departing from the scope of the present invention as defined by the appended claims.