In-Store Refrigerated Display System

This invention generally relates to a refrigerated display system for perishable items. More particularly, this invention relates to an in-store display system for food items which must refrigerated or frozen, wherein the display system includes a refrigeration unit which is reusable, and an attached insulated storage unit which is arranged for the particular food item to be displayed and which is disposable.

Promotions of packaged shelf foods and other times in supermarkets typically takes the form of end aisle displays featuring cases of the food or item to be promoted. In the past, such promotions have been limited to non-perishable items. The manufacturers of frozen or refrigerated foods have been unable to participate in such end aisle promotions because refrigeration or freezing is required and freezers and dairy cases do not allow for the addition of large product specific graphic displays surrounding the promoted product. Indeeded, freezers and dairy cases are expensive items which are not sized for end aisle displays. Moreover, depending on the size and type of item being sold, efficient use of space cannot necessarily be obtained with the use of freezers and dairy cases.

Various solutions to the problem of providing refrigerated display units have been proposed. One solution provides insulated containers with graphics on casters that are stored in a freezer during the night and wheeled out during the day. The problems with such an arrangement are that store personnel are required to attend to the unit each day, and that refrigeration is uneven with the promoted items being frozen at the beginning of the day, and thawed by the end of the day. Another solution to the refrigerated display unit problem has been for companies to purchase small refrigerators and freezers, to apply the graphics to the units, and then to give the stocked units to the food stores. This solution has not been effective because the units are expensive and are typically not size-efficient. Moreover, after the promotion, the units tend to disappear because they have value to the store personnel or to the store itself.

Yet another proposed solution to the refrigerated display system problem has been to provide a disposable insulated container utilizing a battery operated fan and an air hose. One end of the hose is placed in a freezer chest or a dairy case, and the fan pulls the cold air from the freezer or dairy case into the insulated container and keeps the food items refrigerated in that manner. Again, there are several problems with this solution. The unit does not work with vertical freezers with doors. Also, the unit is tied to a freezer or dairy case with a hose which results in the unit being located in the aisle thereby both blocking shopping cart traffic as well as the freezer or dairy case to which the unit is tied. Moreover, such units do not maintain low enough temperatures to keep certain frozen foods, e.g. ice cream, frozen.

Other solutions or related devices known in the art include apparatus disclosed in U.S. Pat. Nos: 1,871,784, C.A. Frick et al.; 2,030,780, R.N. Bicknell; 2,115,048, W.L. Stewart; 2,502,076, H.R. Denton; 2,502,589, L.E. Rabjohn; 3,703,088, G.E. Moorhead; 3,730,603, P. Looms; 4,203,302, J.M. Lapeyre; 4,393,659, Keyes et al.; 4,523,439, B.A. Denisot.

While many of the above-listed patents do provide suggested solutions to the problem in the art, it will be appreciated that each of them are unsuitable for many of the same reasons listed above with regard to the other discussed proposed solutions.

It is therefore an object of the invention to provide a refrigerated system for perishable items which is self-contained and which may be tailored to the size and type of item which is to be promoted.

It is a further object of the invention to provide a self-contained, cost-effective refrigerated display system for perishable items which does not require the attention of store personnel and which is effective in maintaining its refrigeration.

In accord with the objects of the invention, a refrigerated system for perishable items is provided and generally comprises:

(a) a refrigeration unit comprising a cooling means for cooling fluid, a circulation means for circulating the fluid around a disposable insulated storage unit, and at least a first pair of openings in said refrigeration unit for permitting cooled fluid to flow out of said refrigeration through a first opening of said first pair and for permitting returning fluid to be received in said refrigeration unit via a second opening of said first pair; and

(b) said disposable insulated storage unit, separate from said refrigeration unit and arranged for being placed together with said refrigeration unit, said disposable unit further being arranged for storing said perishable items, said disposable unit comprising at least one opening through which at least one of said perishable items can be removed, at least one second pair of openings corresponding to said first pair of openings of said refrigeration unit, means for permitting said cooled fluid passing through a corresponding first opening of said second pair to circulate around said disposable unit before passing through a corresponding second opening of said second pair and back to said refrigeration unit.

Preferably, the fluid used in the system is air, and the means for permitting the air to circulate comprises a fan in conjunction with disposable unit walls having inwardly extending ribs which create passages for the circulating cooled air around for perishable items even if the perishable items completely occupy the usable storage volume. Also, preferably, the means for permitting fluid to circulate further comprises an air plenum which includes a rib structure located in the disposable unit between the refrigeration unit and a plate. The plate forces the air to be directed by the ribs mostly outwardly to the peripheral air passages in the walls. Where the refrigeration unit is located below the disposable display unit, most of the cooled air is forced up the walls of half the disposable dipslay unit, around the top, and down the passages formed by the ribbed walls of the other half of the disposable display unit.

According to the preferred system, the refrigeration unit is arranged with a compressor, condensor coils, and finned evaporator coils to permit the display system to keep perishable items frozen. Regardless of the means for refrigeration, the refrigeration unit should be a reusable item. The separate insulated storage unit, however, is arranged to be a disposable item. Thus, disposable display units of different shapes and sizes may be manufactured for different perishable items so that optimal use of the storage volume may be had, provided of course that the disposable units include duct openings corresponding to those of the refrigeration unit. Moreover, with disposable units, advertising of a promoted product may be had by printing advertising material directly on outer walls of the units or by wrapping the disposable units with a printed wrap. Thus, the display system of the invention is seen to provide an a self-contained, cost-effective refrigerated display system for perishable items which does not require the attention of store personnel and which is effective in maintaining its refrigeration.

A better understanding of the refrigerated display system of the present invention, and additional advantages and objects of the the invention will become apparent to those skilled in the art upon reference to the detailed description and accompanying drawings.

FIG. 1 is a perspective view of an assembled refrigerated display system in accordance with the invention;

FIG. 2 is a vertical sectional view of the refrigerated display system of FIG. 1; and

FIG. 3 is a partially exploded perspective view of the disposable insulated storage and display unit and the refrigeration unit of the refrigerated display system of FIG. 1.

The assembled refrigerated display system 10 in accordance with the invention is seen in FIG. 1 and is seen to include a refrigeration base unit 20, and a disposable insulated storage and display unit 40. One side wall of the refrigeration base unit 20 has a grille 22 for permitting air being pulled across condensor coils to escape. While, if desired, the refrigeration base unit may be powered by a portable generator contained therewith, preferably, the unit is powered by standard electrical wall current. Toward that end, an electrical wire 24 terminating on one end in a plug (not shown) and at the other end in a power supply for a compressor 25 (seen in FIG. 2) is provided.

The disposable insulated storage and display unit 40 as seen in FIG. 1 has printed graphics 43 on all four sides (only two sides being shown) which ostensibly advertise the promoted perishable product being stored in the plenum. A door 44 with plastic hinges 45 (seen in FIG. 3), and with a pull knob 46 is located on the top of the disposable unit 40 and permits the unit to be loaded with the perishable product as well as permitting a consumer to reach inside the unit 40 to obtain the product. As shown in FIG. 1, the disposable unit 40 has a larger cross-sectional area than the cross sectional area of the base unit. Of course, the unit 40 could be of different sizes and shapes, provided that the duct openings in the unit for permitting cooled fluid (in this case air) to circulate correspond to the similar openings in the refrigeration unit 20, and further that some means for supporting the disposable unit 40 and the perishable product to be contained therein is provided. In fact, because the storage and display unit 40 is disposable, it is anticipated that units of different shapes and sizes may be manufactured for different perishable items so that optimal use of the storage volume may be had. Thus, a supplier of perishable items could have a storage and display unit 40 of a desired size with desired graphics printed on the walls (or as a wrap) manufactured to his specifications. For example, a supplier of large frozen pizzas might desire a round storage unit to be manufacutured so that the pizzas may be effectively stacked one atop the other. A picture of the pizza and the name of the product might appear on the foam insulating walls of the disposable unit 40.

Turning to the sectional view of FIG. 2, some details of the refrigerated display system are seen. In the preferred embodiment, the means used by the refrigeration unit 20 for cooling the air includes a compressor 25, a condensor 28 and associated fan 29, and evaporator coils 30. As is typical of a refrigeration unit, the compressor 25 takes gas such as freon and pressurizes it, thereby raising its temperature and pressure. This pressurized gas flows to the condensor coil 28. At the condensor coil, air is pulled by fan 29 over the condensor coils to cool the pressurized gas which, as a result, condenses into a liquid. The cooled, pressurized liquid is then pumped to the evaporator coils 30 where the pressure is released. In order to vaporize, the liquid absorbs heat from its surroundings. Because the evaporator coils preferably have large surface areas (e.g. fins) heat is quickly absorbed from the air passing over the fins, thereby cooling the air. The depressurized expanded gas is then returned from the evaporator 30 to the compressor 25 where the gas is then repressurized to complete the closed loop.

The evaporator 30 of the refrigeration unit 20 is preferably contained in a substantially enclosed insulated chamber 32 which includes a first duct 34 through which air flows out of the chamber and into the disposable storage and display unit 40, and a second duct 36 through which air returns from the disposable unit 40 into the chamber 32. In establishing and maintaining the flow of air, a fan 38 is preferably utilized to provide a pressure difference. Thus, air returning from unit 40 through duct 36 is pushed (pulled) across the evaporator 30 where it is cooled, and the pushed out (pulled) through duct 34 into the disposable unit 40. It will be appreciated that for purposes herein, the term "duct" is being used in its broadest sense as an air passage, such that any opening in the chamber 32 through which air may be pulled should be considered a duct even if the opening is not three dimensional.

Turning to FIG. 3, the details of the disposable insulated storage and display unit 40 are seen. The base 50 of unit 40 is preferably made out of corregated cardboard which is cut to a desired shape and size. Cut out of the cardboard are openings or "ducts" 54 and 56 which cooperate with and correspond to ducts 34 and 36 of the refrigeration unit 20 to permit air to flow therethrough. Also preferably provided are holes 57a, 57b, 57c, and 57d which correspond to similar holes 37a-37d (hole 37b not shown) in the refrigeration unit 20 through which plastic screws 77a-77d (screws 77b and 77d not shown) can extend so as to hold the disposable unit 40 in place with respect to the refrigeration unit 20. The corrugated base 50 is preferably die cut to order.

Directly above the corregated base 50, is an insulated plate 60 having "duct" openings 64 and 66 which correspond to the ducts of the base plate 50 and the ducts of the refrigeration unit 20, and holes 67a-67d (hole 67b not shown) which correspond to holes 57a-57d and 37a-37d. As aforementioned, plastic screws 77a-77d, which may be used with washers 79a-79d (washers 79b and 79d not shown), are extended through holes 67a-67d so as to hold the disposable unit 40 in place relative to the refrigeration unit 20. Insulated plate 60 also has groups of ribs 68a, and 68b, and a divider rib 68c which act in conjunction with corregated plate 80 as a plenum to direct the cooled air in desired directions. Thus, cooled air forced out of refrigeration unit 20 through duct 34, proceeds through ducts 54 and 64, and is forced towards the periphery of the disposable storage and display unit 40 by the air passages formed by ribs 68a, plate 60 and plate 80. As indicated, divider rib 68c acts to cause substantially all of the incoming cooled air to stay in a half plane; i.e. the incoming air is sent to the peripheral walls comprising half to the outside walls of the disposable unit 40. As will be discussed hereinafter, ribs 68b conversely act to direct the air returning from the walls of the other half plane of unit 40 into duct 66 for return through ducts 56 and 36 to the refrigeraton unit.

The walls 85 of storage and display unit 40 are preferable relatively thick insulated interlocking polystyrene foam panels which have inwardly extending ribs 87. The provision of ribs 87 provides channels through which the cooled air may circulate about the perishable items which are stacked atop corregated plate 80. Without ribs 87, if the storage area of disposable unit 40 were completely filled with perishable items, there might be little room for the cool air to circulate and keep the perishable items refrigerated. However, with longitudinally extending ribs 87, the cooled air is free to flow up the walls 85, provided the perishable items are not small enough to extend between the ribs. Thus, the cooled air is permitted to envelop the perishable items, keeping them refrigerated. If desired, the channels formed by ribs 87 may be enclosed by adding walls which are substantially coplanar to and internal the outer walls 85. The channels may be enclosed along part or even all of the walls in either or both of the walls handling the outgoing and returning air. Such a closed channel arrangement provides a partial or complete vertical plenum which could provide more direction to the air flow, if desired.

Sitting atop the walls 85 of disposable unit 40 is a top cover 90 and associated insulation 92. Cover 90 has a central cut-out 91 for permitting the perishable items to be loaded into and removed from the storage and display unit 40. Insulation 92 also includes a central cut-out 93. Central cut-out 91 of cover 90 is formed to accept door 44 and hinge 45 which connects the door 44 to the top cover 90. Door 44 is preferably of a thermopane construction with a vinyl bottom, and snugly sits in cover 90 so as to block the exit and entrance of air therethrough except when opened.

There has been described and illustrated herein a preferred refrigerated display system. While a particular embodiment of the invention has been described, it is not intended that the invention be limited thereby, as it is intended that the invention be as broad in scope as the art will allow. Thus, while the invention has described as having a refrigeration unit which utilizes a compressor, condensor, and evaporator, those skilled in the art will appreciate that other means for cooling air (such as a thermoelectric device) could be utilized. Similarly, while the disposable unit was described as utilizing corregated cardboard and foam, other insulative materials could be utilized. Further, it will be appreciated that while a plenum of the disposable unit was described as using rib means extending from plates (and the walls were described as using ribs) for distributing the cooled air around the perishable items, other means for distributing the air could be utilized. In fact, while the results would be inferior, the cooled air could be forced to circulate around the disposable unit by passing through air gaps between the stored perishable items if desired. Thus, for example, instead of utilizing an air plenum, a perforated plate could be used to both act as a base for holding the perishable items and as a means or permitting the air to rise out of duct 34 and back through duct 36.

Another change to the preferred arrangement which would be considered within the scope of the invention would be to locate the disposable unit adjacent the refrigeration unit in a side-by-side manner, or even having the disposable unit below the refrigeration unit rather than having the refrigeration unit below the plenum as shown. Clearly, the ducting of the air would have to be changed to accommodate the same. It will further be appreciated that the ducting of the air could be changed and still be within the scope of the invention. For example, rather than having the cooled air rise along half of the perimeter of the disposable unit, and descend along the other half, different percentages (other than 50-50) for rising and descending along the periphery could be utilized as well as different arrangements (e.g. interleaved sections). Indeed, as previously implied, the disposable unit need not even be divided into different sections such that the cooled air rises along one section and descends along the other. Further, it will be appreciated that the "door" to the disposable unit can take many forms and locations, and is intended to be understood broadly to include any means which may be opened to give access to the storage area of the disposable unit and then shut to prevent the cooled air from escaping. In fact, a door is not even necessary in certain circumstances as the air loss through a provided opening would not necessarily render the system inoperable. Likewise, it will be appreciated that while the terminology used herein has referred to "refrigeration" and "refrigerated", those terms are intended to encompass freezing also. Indeed, with the preferred embodiment described herein, temperatures of minus ten degrees F are definately maintainable. Similarly, terms such as fluid or air flow "about" the storae unit is to be broad language intended to encompass peripheral flow as well as flow through the middle of the unit.

Yet another arrangement within the scope of the invention is to utilize another gas or a liquid cooling means rather than air. Where a liquid is used, tubing is preferably provided as the means for permitting the fluid to circulate, as well as providing a manner for eliminated leaks. Therefore, it will be apparent to those skilled in teh art that yet other changes and modifications may be made to the invention as described without departing from the scope of the invention as so claimed.