U.S. patent application number 09/755938 was filed with the patent office on 2002-07-11 for point of sale product chiller.
Invention is credited to Bertrand, Stephen E., Jennings, Thomas A., Pierce, Eugene C. III, Pierce, Theodore A..
Application Number | 20020088244 09/755938 |
Document ID | / |
Family ID | 25041324 |
Filed Date | 2002-07-11 |
United States Patent
Application |
20020088244 |
Kind Code |
A1 |
Jennings, Thomas A. ; et
al. |
July 11, 2002 |
POINT OF SALE PRODUCT CHILLER
Abstract
An improved point-of-sale product chiller that is modular in
design and construction whereby the server may be readily produced
in various sizes and capacities for point-of-sale display and sale
of chilled products. An insulated enclosure includes a base panel,
a pair of sidewall panels, and a plurality of modular end wall
panels that form a chilled product cavity. The panels are formed of
hollow, blow-molded thermoplastic with foam insulation panels
inserted therein. A chiller of a desired size is produced by
selecting a base panel of the desired size and assembling to it
modular end wall panels and sidewall panels of the desired size.
One or more insulated central divider panels may be assembled
within the enclosure to form multiple chilled product cavities
within the enclosure. Removable, flat cold cell panels having
cooperating edges are inserted about the inner periphery of the
enclosure to maintain product temperatures inside the cavities.
Inventors: |
Jennings, Thomas A.;
(Winston-Salem, NC) ; Pierce, Theodore A.;
(Pfafftown, NC) ; Pierce, Eugene C. III;
(Greensboro, NC) ; Bertrand, Stephen E.;
(Winston-Salem, NC) |
Correspondence
Address: |
RHODES & MASON, P.L.L.C.
P.O. BOX 2974
GREENSBORO
NC
27402
US
|
Family ID: |
25041324 |
Appl. No.: |
09/755938 |
Filed: |
January 5, 2001 |
Current U.S.
Class: |
62/371 ;
62/457.2; 62/530 |
Current CPC
Class: |
F25D 2331/804 20130101;
F25D 21/14 20130101; F25D 3/06 20130101; F25D 23/063 20130101; F25D
2400/16 20130101; F25D 2400/38 20130101; F25D 23/026 20130101; A47F
3/0404 20130101; F25D 2500/02 20130101; F25D 2201/126 20130101;
G07F 9/105 20130101; F25D 23/069 20130101; F25D 23/021 20130101;
F25D 29/005 20130101; F25D 2303/082 20130101 |
Class at
Publication: |
62/371 ;
62/457.2; 62/530 |
International
Class: |
F25D 003/08 |
Claims
What is claimed is:
1. A modular, point-of-sale, product chiller comprising: a base
panel having a top face and a bottom face, a pair of insulated
sidewall panels each having an inside face and an outside face, a
pair of insulated end wall panels each having an inner face and an
outer face, and a plurality of removable cold cell inserts having
vertical edges and positioned along the inside faces of the
sidewall panels and the inner faces of the end wall panels, wherein
the sidewall panels and end wall panels define a rectangular,
upwardly-extending cavity for containing product to be
dispensed.
2. The point-of-sale product chiller claimed in claim 1 further
including: one or more foam insulation panels atop the top face of
the base panel, and a moisture tray covering each foam insulation
panel and nested between the adjacent inside faces of the sidewall
panels and inner faces of the end wall panels.
3. The point-of-sale product chiller claimed in claim 1 wherein the
insulated sidewall panels and end wall panels each include a hollow
outer shell and an insulating foam panel insert contained
therein.
4. The point-of-sale product chiller claimed in claim 3 wherein the
hollow outer shells of the sidewall panels and end wall panels and
the base panel are formed of blow-molded plastic.
5. The point-of-sale product chiller claimed in claim 1 wherein the
removable cold cell inserts are sized and shaped to abut each other
at their vertical edges and the abutting vertical edges are
configured to matingly engage each other to provide lateral support
between adjacent cold cells.
6. The point-of-sale product chiller claimed in claim 1 further
including: one or more insulated vertical central divider panels
each having a first and second face and extending laterally between
the inner faces of opposite end wall panels, and a removable
central cold panel insert adjacent each first face and second face
of each central divider panel.
7. The point-of-sale product chiller claimed in claim 6 wherein
each central divider panel includes a hollow outer shell and an
insulating foam panel insert therein.
8. The point-of-sale product chiller claimed in claim 7 wherein the
hollow outer shell of each central divider panel is formed of
blow-molded plastic.
9. The point-of-sale product chiller claimed in claim 6 wherein the
removable cold panel inserts adjacent each first and second face
have vertical edges which abut the vertical edges of the adjacent
cold cell inserts along the inner faces of the nearest end wall
panels, and the vertical edges of the adjacent cold cells are
configured to matingly engage each other to provide lateral support
between the adjacent cold cells.
10. The point-of-sale product chiller claimed in claim 1 further
including one or more vertical central cold cell inserts extending
laterally between opposite inner faces of the end wall panels and
having side edges which abut the vertical edges of adjacent cold
cells along the inner faces of the end wall panels, wherein the
side edges and vertical edges are configured to matingly engage
each other to provide lateral support between the adjacent cold
cell inserts.
11. The point-of-sale product chiller claimed in claim 1 further
including a graphics area on the outer face of each end wall panel,
replaceable indicia over the graphics area, and a removable
transparent side panel overlaying the removable indicia and
graphics area.
12. The point-of-sale product chiller claimed in claim 1 further
including a signage area on the outside face of each sidewall
panel, replaceable indicia over the signage area, and a removable
transparent end panel overlaying the removable indicia and signage
area.
13. The point-of-sale product chiller claimed in claim 1 further
including a plurality of casters mounted on the bottom face of the
base panel.
14. The point-of-sale product chiller claimed in claim 1 further
including a thermometer having a temperature sensing probe in an
interior region of the chiller and a temperature readout on an
outer surface of the chiller.
15. The point-of-sale product chiller claimed in claim 1 further
including a movable lid covering the upwardly extending cavity.
16. The point-of-sale product chiller claimed in claim 15 wherein
the movable lid includes a plurality of transparent panels in
overlapping, sliding arrangement over the upwardly extending
cavity.
17. The point-of-sale product chiller claimed in claim 15 wherein
the movable lid includes a transparent hinged cover over the
upwardly extending cavity.
18. The point-of-sale product chiller claimed in claim 1 further
including reinforcement rods in the base panel.
19. A modular point-of-sale product chiller comprising: a base
panel having a top face and a bottom face including a plurality of
casters mounted to the bottom face; a pair of insulated sidewall
panels each having an inside face and an outside face, and having a
hollow outer shell of blow-molded plastic with an insulating foam
panel insert contained therein; a plurality of modular
interchangeable insulated end wall panels each having an inner face
and an outer face, and having a hollow outer shell of blow-molded
plastic with an insulating foam panel insert contained therein; one
or more insulated vertical central divider panels each having a
first and second face, having a hollow outer shell of blow-molded
plastic with an insulating foam panel insert contained therein, and
extending laterally between opposite inner faces of the end wall
panels; one or more foam insulation panels atop the top face of the
base panel and a moisture tray covering each foam insulation panel
and nested between the faces of adjacent end wall and sidewall
panels, a plurality of removable cold cell inserts having vertical
edges and positioned along the inside faces of the sidewall panels,
the inner faces of the end wall panels, and the first and second
faces of each central divider panel, wherein the vertical edges of
adjacent cold cell inserts are configured to matingly engage each
other to provide lateral support between the adjacent cold cell
inserts; a graphics area on an outer face of at least one of the
end wall panels or sidewall panels, replaceable indicia over the
graphics area, and a removable transparent lens panel overlaying
the removable indicia and graphics area; a thermometer having a
temperature sensing probe in an interior region of the chiller and
a temperature readout on an outer surface of the chiller; wherein
the sidewall panels, end wall panels, and cold cells form an
upwardly extending chilled product-dispensing opening, with a
plurality of transparent covers in sliding arrangement over the
opening.
20. A method of dispensing chilled products comprising: providing
an enclosure formed of modular insulated panels and having inner
wall surfaces and an upwardly extending product-dispensing opening,
lining the inner wall surfaces of the enclosure with removable
chilled panels having vertical edges configured to matingly engage
one another to provide lateral support therebetween and together
forming a chilled product cavity within the enclosure, placing
chilled food items in the chilled product cavity, and dispensing
the chilled food items through the product-dispensing opening.
21. The method claimed in claim 20 further including: providing a
movable lid on the enclosure over the product-dispensing opening,
and opening the movable lid to dispense the chilled food items.
22. The method claimed in claim 20 further including providing
replaceable signage on outer surfaces of the enclosure to advertise
product in the enclosure to customers.
23. The method claimed in claim 20 further including providing
casters on a bottom of the enclosure and moving the enclosure on
the casters to the point-of-sale.
24. The method claimed in claim 20 further including providing one
or more vertical central cold cells to divide the chilled product
cavity into multiple chilled sections for receiving and dispensing
chilled food items, each central cold cell having vertical edges
configured to matingly engage vertical edges of the removable cold
cells lining the inner walls of the cavity whereby the central cold
cells are laterally supported at the vertical edges.
25. A process for producing modular point-of-sale product chillers
of variable size comprising: producing insulated end panels in
various widths and including inner and outer surfaces; producing
insulated side panels in various widths and including inner and
outer surfaces; producing incrementally-sized base panels sized in
lengths and widths corresponding to various widths of produced end
panels and side panels; producing removable cold cells in widths
corresponding to the various widths of end panels and side panels;
selecting and assembling two end panels and two side panels on each
base panel of corresponding size; and selecting and assembling the
cold cells of corresponding widths along the inner surfaces of the
end panels and side panels.
26. The process claimed in claim 25 wherein producing insulated end
panels and side panels includes blow-molding hollow plastic outer
shells and inserting insulating foam panels therein.
27. A process for producing modular point-of-sale product chillers
of variable size comprising: providing molds for blow-molding
sidewall panels, end wall panels, and base panels including
removable mold sections for adapting the molds to produce panels of
various widths; producing base panels, sidewall panels, and end
wall panels of desired widths in the molds; selecting and
assembling the sidewall panels and end wall panels together on the
base panels to form chiller enclosures of desired sizes; and
providing removable cold cells in widths corresponding to the
desired widths of the end panels and side panels and assembling the
cold cells along the inner surfaces of the enclosure.
28. The process claimed in claim 27 further including: providing a
mold including one or more removable mold sections for adapting the
mold to blow-mold central divider panels of various widths;
producing central divider panels of desired widths in the mold;
assembling the divider panels in the enclosures to form multiple
product cavities in the enclosures; and providing removable cold
cells in widths corresponding to the desired sizes of the end
panels, side panels, and divider panels and assembling the cold
cells along the inner surfaces of the end wall and sidewall panels
and along each face of each divider panel.
29. The process claimed in claim 28 wherein the mold for blow
molding end wall panels in various widths and the mold for blow
molding divider panels in various widths is a single mold that
yields common panels having an end wall edge on one end and a
divider edge on an opposite end, producing end wall panels includes
removing the divider edges from the common panels, and producing
divider panels includes removing the end wall edges from the common
panels.
30. A point of sale product chiller comprising: an outer insulating
shell having a bottom and end walls defining a cavity, a plurality
of flat, removable cold cell inserts sized to fit along inside
walls of the cavity and having edge shapes to cooperate with edge
shapes of others of the removable cold cell inserts together with
the end walls to hold the cold cell inserts upright in the
cavity.
31. A chiller as claimed in claim 29 wherein one edge shape is
convex and a cooperating edge shape is a concavity in which the
convex edge can fit.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to insulated containers for
the protection of temperature sensitive goods and more particularly
to an insulated container for the display and sale of chilled
products at point-of-sale locations in stores, convenience stores,
cafeterias, eateries, lunchrooms, hotels, outdoor pavilions, theme
parks, county fairs, catered events, sports arenas, stadiums,
convention centers, and the like.
[0002] Generally, for keeping temperature-sensitive foodstuffs,
especially beverages, chilled, either an electrically refrigerated
cabinet or an insulated container filled with ice has been used.
For example, as a student passes through the lunch line he/she
usually passes a large electrically refrigerated cabinet filled
with cartons of milk. Also, convenience stores generally have
point-of-sale insulated containers filled with iced-down beverages.
There are numerous problems associated with either method of
cooling individually packaged beverages as discussed in the
specification of U.S. Pat. No. 6,067,810 assigned to the assignee
of the present applicant.
[0003] For example, traditional electrically refrigerated cabinets
are large and cumbersome, and are difficult to access by small
persons or children. The units are not easily movable and this
prevents convenient rearrangement of the store, eatery or lunch
line as needed. These cabinets generally require a substantial
capital investment. Additionally, as with other similar appliances,
the units require periodic maintenance. If the unit fails or a
power outage occurs, the units are ineffective during the
interim.
[0004] As a solution to the aforementioned shortcomings to an
electrically refrigerated unit, insulated beverage coolers have
been made that chill the beverages with ice in an attractive
display. These coolers are basically large tubs that hold
individually packed beverages together with ice, thus keeping the
beverages in contact with the ice and cooled. Although these
coolers are generally more mobile and convenient, they also are
fraught with drawbacks.
[0005] Placing food or beverages on ice, although the food or
beverage may be individually packaged, allows for the opportunity
for contamination to the food or beverage by the melted ice.
Sometimes the preferred product is packaged in a carton, like milk,
and the carton becomes soggy after prolonged contact in ice and
melted water. The melted ice may splash and spill out of the
cooler, thus creating a slip-and-fall hazard. The beverages
eventually may become completely immersed within the ice and water.
This is inconvenient and also presents a health risk due to the
spread of germs within the ice and water mixture. The accumulation
of water as a cooling medium has the undesirable effect of
impairing the degree of sanitation achievable and maintainable.
There is a need, therefore, for a chilled beverage container that
can maintain the required cooling effect on its contents while
being mobile, efficient, sanitary, and inexpensive.
[0006] Decision Point Marketing, Inc. of Winston-Salem, N.C., has
addressed this need by providing chilled item servers that require
no electricity or loose ice. Exemplary of the chilled item servers
marketed by Decision Point Marketing are the devices disclosed by
U.S. Pat. No. 6,067,810 and pending U.S. patent application Ser.
Nos. 09/578,575 filed May 25, 2000, and 09/301,709 filed Apr. 29,
1999, the disclosures of which are hereby incorporated by
reference. These devices generally include portable insulated
containers having inner cavities lined with removable cold cells.
The cold cells are formed of thermoplastic and have hollow cores
filled with 1%-5% saline solution that can be frozen by placing the
panels in a conventional freezer. Beverages are placed within the
servers and subjected to the cool atmosphere created within the
servers by the cold cells and are thereafter maintained at an
effective temperature for consumption.
[0007] While the chilled item servers supplied by Decision Point
Marketing have proven effective to eliminate the problems
associated with electric or ice coolers, they may not be optimally
sized for some point-of-sale applications. Because the overall size
and capacity of each of these devices has been intentionally
designed to address specific uses in the marketplace, they cannot
be optimally adapted on a commercial scale to meet widely varying
demands for units of different sizes or capacities. In particular,
the cost of providing multiple molds of various shapes and sizes to
produce an assortment of incrementally sized thermoplastic
enclosures for these servers would be burdensome. Therefore, a need
exists for an improved point-of-sale product chiller that can be
economically produced in various sizes and capacities to address a
broad range of market demands for such devices.
SUMMARY OF THE INVENTION
[0008] The present invention addresses this need in the art by
providing a point-of-sale product chiller that includes a base
panel having a top face and a bottom face, a pair of insulated
sidewall panels each having an inside face and an outside face, and
a plurality of modular, interchangeable, insulated, end wall panels
each having an inner face and an outer face. A plurality of
removable cold cell inserts having vertical edges are positioned
along the inside faces of the sidewall panels and the inner faces
of the end wall panels. The sidewall panels and end wall panels
define a rectangular, upwardly-extending cavity for containing
chilled product to be dispensed.
[0009] One or more bottom insulation panels may sit atop the top
face of the base panel. A moisture tray with an upwardly extending
lip may cover each bottom insulation panel so the lip fittingly
engages the inside face of each adjacent sidewall panel and the
inner face of each adjacent end wall panel. Preferably, the
insulated sidewall panels and end wall panels each include a hollow
outer shell with an insulating foam panel insert therein. These
hollow panels are preferably formed of blow-molded thermoplastic.
The removable cold cell inserts are sized and shaped to abut each
other at their vertical edges, and the abutting vertical edges are
configured to matingly engage each other to provide lateral support
between adjacent cold cells in the chiller.
[0010] The chiller may be divided into multiple, rectangular,
upwardly-extending cavities by including one or more insulated
vertical central divider panels, each having a first and second
face and extending laterally between the inner faces of opposite
end wall panels. Preferably, each central divider panel includes a
hollow outer shell with an insulating foam panel insert therein.
The hollow outer shell of each central divider panel may be formed
of blow-molded thermoplastic. A removable central cold panel is
inserted adjacent each first face and second face of each central
divider panel to surround each rectangular cavity with cold cells.
In a preferred arrangement, the removable cold panel inserts
adjacent each first and second face have vertical edges which abut
the vertical edges of the adjacent cold cell inserts along the
inner faces of the nearest end wall panels. The vertical edges of
the adjacent cold cells are configured to matingly engage each
other to provide lateral support between the adjacent cold
cells.
[0011] Alternatively, the chiller may include one or more vertical
central cold cell inserts in lieu of central divider panels for
dividing the enclosure into multiple cavities. These vertical
central cold cell inserts extend laterally between opposite inner
faces of the end wall panels and have side edges that abut the
vertical edges of adjacent cold cells along the inner faces of the
end wall panels. The side edges and vertical edges of the cold
cells are configured to matingly engage each other to provide
lateral support between the adjacent cold cell inserts.
[0012] Because it may be desirable to promote or advertise products
on the outside of the chiller or simply to decorate the chiller, a
graphics area may be included on the outer face of each end wall
panel for receiving replaceable indicia. A removable transparent
side panel overlays the removable indicia and graphics area.
Similarly, a signage area with replaceable indicia and a removable
transparent end panel overlaying the indicia may be provided on the
outside face of each sidewall panel.
[0013] A plurality of casters may be mounted on the bottom face of
the base for convenient movement of the chiller. Also, a
thermometer with a temperature-sensing probe in an interior region
of the chiller and temperature readout on an outer surface of the
chiller may be provided for conveniently monitoring the internal
temperatures of the chiller. A movable lid may be included to cover
each upwardly extending cavity. Preferably, the movable lid
includes a plurality of transparent panels in overlapping, sliding
arrangement over the upwardly extending cavity. Alternatively, the
lid may be hinged along one edge of the cavity. For added rigidity
and strength, reinforcement rods may be mounted at the top of the
end panels and center panels to hold the panels together.
[0014] The invention also provides a method of dispensing chilled
products. First, an enclosure is provided formed of modular
insulated panels and having inner wall surfaces and an upwardly
extending product-dispensing opening. Second, the inner wall
surfaces of the enclosure are lined with removable chilled panels
having vertical edges configured to matingly engage one another to
provide lateral support therebetween and together forming a chilled
product cavity within the enclosure. Third, chilled food items are
placed in the chilled product cavity. Finally, chilled food items
are dispensed through the product-dispensing opening.
[0015] This method may further include providing a movable lid on
the enclosure over the product-dispensing opening, and opening the
movable lid to dispense the chilled food items. The method may also
include providing replaceable signage on outer surfaces of the
enclosure to advertise or promote product in the enclosure to
customers. Furthermore, the method may include moving the enclosure
on casters to the point-of-sale. Also, the method may include
installing one or more vertical central cold cells having vertical
edges configured to matingly engage vertical edges of the cold
cells lining the inner walls of the cavity so the central cold
cells are laterally supported at their vertical edges and divide
the chilled product cavity into multiple chilled sections for
receiving and dispensing chilled food items.
[0016] The invention also provides a process for producing modular
point-of-sale product chillers of variable size. The process
includes producing insulated sidewall panels and end wall panels in
various widths and producing incrementally-sized base panels sized
in lengths and widths corresponding to the various sizes of end
panels and side panels. Removable cold cells are produced in widths
corresponding to the various widths of end panels and side panels.
Two end panels and two side panels are selected and assembled on
each base panel of corresponding width and length. Cold cells of
corresponding widths are selected and assembled along inner
surfaces of the end panels and side panels. The process may include
producing insulated sidewall panels and end wall panels by
blow-molding hollow plastic outer shells and inserting insulating
foam panels therein.
[0017] Preferably, the process for producing modular point-of-sale
product chillers of variable size includes providing molds for
blow-molding sidewall panels, end wall panels, and base panels that
include removable mold sections for adapting the molds to produce
panels of various widths. Once base panels, sidewall panels, and
end wall panels of desired sizes are produced in the molds,
compatible panels are selected and assembled together to form
chiller enclosures of desired sizes. Removable cold cells are
provided in widths corresponding to the desired widths of the
sidewall panels and end wall panels and assembled along the inner
surfaces of the enclosure. The process may further include
providing a mold including one or more removable mold sections for
blow-molding central divider panels of various widths and producing
central divider panels of desired widths in the mold. The divider
panels are assembled in the enclosures to form multiple product
cavities in the enclosures. Removable cold cells are provided in
corresponding widths and assembled along the inner surfaces of the
end wall and sidewall panels and along each face of each divider
panel in the product cavities.
[0018] The process may also include a single mold for blow molding
both the end wall panels and the divider panels in various desired
widths. The single mold yields common panels including an end wall
edge on one end and a divider edge on an opposite end. The divider
edges are cut from the common panels to produce end wall panels.
Similarly, the end wall edges are cut from the common panels to
produce divider panels.
[0019] The invention also provides a point of sale product chiller
including an outer insulating shell having a bottom and end walls
defining a cavity, and a plurality of flat, removable cold cell
inserts sized to fit along inside walls of the cavity and having
edge shapes to cooperate with edge shapes of others of the
removable cold cell inserts together with the end walls to hold the
cold cell inserts upright in the cavity. In a preferred
arrangement, one edge shape is convex and a cooperating edge shape
is a concavity in which the convex edge can fit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a top view of one embodiment of the invention.
[0021] FIG. 2 is a front view of the embodiment shown in FIG.
1.
[0022] FIG. 3 is a cross-sectional view of the embodiment of FIG. 1
and FIG. 2 taken through line 3-3 as indicated in FIG. 2.
[0023] FIG. 4 is a top cross-sectional view of a corner of the
embodiment of FIGS. 1-3 taken through line 4-4 as indicated in FIG.
3.
[0024] FIG. 5 is a top sectional view of a second embodiment of the
invention taken through line 5-5 as indicated in FIG. 6.
[0025] FIG. 6 is a front view of the embodiment of FIG. 5 showing a
partial section taken through line 6-6 as indicated in FIG. 5.
[0026] FIG. 7 is a top view of a third embodiment of the
invention.
[0027] FIG. 8A is a top view of a fourth embodiment of the
invention.
[0028] FIGS. 8B and 8C show details of cold cell edge shapes and
interfaces as indicated in FIG. 8A.
[0029] FIG. 9 is an exploded isometric view of the chiller shown in
FIGS. 5 and 6.
[0030] FIGS. 10A and 10B are section views of molds for
enclosure.
[0031] FIG. 11 is a cross-sectional view of a common panel for
making both end wall and divider panels.
[0032] FIG. 12 is an enlarged detail of the cross-section shown in
FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The present invention provides an improved point-of-sale
product chiller that is modular in design and construction and can
be easily and economically adapted to various sizes and
configurations. A first embodiment of the invention is shown in
FIGS. 1-4. An insulated enclosure 20 includes a base panel 22, a
pair of sidewall panels 24, and a pair of end wall panels 26.
Removable cold cells 28a and 28b are assembled along the inner
faces of the sidewall panels 24 and end wall panels 26 to form a
chilled product cavity 27 in the enclosure with an upwardly
extending product-dispensing opening 29. Details of the
construction can be seen in FIG. 3 and FIG. 4.
[0034] The base 22, sidewall panels 24, and end wall panels 26 are
formed of blow-molded thermoplastic and have hollow centers. The
blow molding results in panels that have inside and outside walls
joined by top and left and right walls, bounding a cavity. Other
molding methods may be used, but blow molding is preferred as being
versatile and inexpensive.
[0035] As seen in FIG. 4, the abutting edges of the end wall panels
26 and sidewall panels 24 may include mortises 25 and tenons 23
that engage to add rigidity and stability to the apparatus. As seen
in FIGS. 3 and 12, the upper face of the bottom panel 22 has tenons
80 that engage slots in the lower ends of end wall and sidewall
panels. Foam insulation panels 30 are located inside the hollow
sidewall panels 24 and end wall panels 26. Alternatively,
insulation can be injected or otherwise located in the panels. If
preferred, other insulating materials can be used. The base 22 has
a substantially flat upper face. A bottom insulation foam panel 34
lays on the upper face of the base 22 and is covered by a moisture
tray 36 that nests in the bottom of the cavity 27. The moisture
tray 36 collects condensation or spills inside the server, and is
removable for cleaning. As best seen in FIG. 9, the molded plastic
base 122, end wall panels 126 and end panels 124 can be joined by
conventional hardware items such as connecting rods having threaded
ends 170, screws 172, bolts 178, nuts 174, and washers 176 and the
like. As shown in FIG. 3, reinforcement rods 47 made of steel or
the like may be mounted in the base panel for added rigidity and
strength.
[0036] The chilled product cavities 27, 127, 227, and 327 may be of
any desired size, but are preferably sized to accept standard
chilled product containers such as milk crates or beer cases, for
ease of loading and unloading the server. For example, the
embodiment illustrated in FIG. 1 is configured to accept two
standard, 24-quart dairy crates stacked one atop the other. Casters
32 are provided on the bottom of the base panel 22 for ease of
movement of the server.
[0037] The removable cold cells 28a and 28b include hollow plastic
shells containing a two-percent saline solution or other suitable
freezing medium. The cold cells may be placed in a conventional
freezer until the saline solution becomes frozen. The frozen cold
cells are then assembled into the enclosure. Multiple
interchangeable sets of cold cells may be used to continuously
chill product in the server by replacing warmed cold cells with
newly frozen cold cells when necessary. In a preferred arrangement,
the panels can be removed from the top of the server without
removal of any product already in the server.
[0038] As best seen in FIG. 4, the vertical edges 70 and 72 of the
cold cells abut one another and mate together to laterally support
one another when assembled in the enclosure, as shown. Other mating
edge configurations may also be used to provide similar support
between the cold cells, like that shown in FIGS. 8A, 8B, and 8C.
Because a cold cell can be heavy to handle when the length and/or
the width of the panel is great, it is preferable to minimize the
size of each cold cell. As seen in FIG. 3, a plurality of short
cold cells 28c may be provided and stacked as shown in lieu of a
taller and heavier cold cell 28a. Hand-holes 31 care provided in
each cold cell to facilitate handling, removal, and insertion of
the cells.
[0039] The invention also provides for replaceable signage on the
outside of the server to promote and/or advertise chilled items in
the server to consumers or to provide other displays. As seen in
FIGS. 2-4, signage areas 40 are provided on one or more of the
outer faces of the sidewall panels 24 and end wall panels 26. A
sign panel 42 is placed over the area 40 and is secured in place
and protected by a transparent lens panel 44. Preferably, the sign
panel 42 is heavy paper or cardstock. The lens panel 44 is secured
by lens retainer strips 46 attached along the periphery of the
signage area 40. Advertising indicia 43 is printed on the outer
face of the sign panel 42 and is visible through the transparent
lens panel 44. The lens panel 44 is preferably somewhat flexible,
so that it can be distorted, if desired, for removal from the
strips 46. This enables the sign panel 42 to be replaced with a
different sign panel 42 that promotes a different product, uses a
different promotional campaign for the same product, or includes
other graphics.
[0040] As seen in FIGS. 6 and 9, the server may be provided with a
movable cover mounted over the openings 129. The movable cover
includes a plurality of sliding lids 152a and 152b, mounted in
sliding arrangement on the top of the server above the
product-dispensing openings 129. A frame 154 supports and guides
the sliding lids 152a and 152b . Handles 156 are provided for
gripping to open and close the lids. Preferably, the sliding lids
are transparent to permit a customer to view the contents in the
server when the lids are closed. Alternatively, a hinged cover may
be included.
[0041] The server may also include a thermometer for monitoring the
temperature inside the chilled product cavities. A readout display
160 is mounted on an upper edge of the server. The display 160 is
connected to a temperature-sensing probe 162 located in a chilled
product cavity 127. Preferably, the thermometer and readout are
digital. Multiple thermometers may be included for servers having
more than one chilled product cavity. The thermometers indicate
when the temperature inside the chiller has warmed sufficiently
that the cold cells should be replaced with newly frozen
panels.
[0042] Details of the construction of the invention and
specifically the embodiment of FIGS. 5 and 6 are best seen in the
exploded isometric view of FIG. 9. In this embodiment, the end wall
and sidewall panels 124 and 126 are provided with mating mortises
125 and tenons 123 for rigidity and stability of the joined panels.
The bottom panel 122 includes bottom tenons 180 on its upper face
which engage mating openings in the lower ends of the end wall
panels 126, sidewall panels 124, and central divider panels 150, if
any. Foam insulation panels 130 are inserted into the end wall and
sidewall panels. Casters 132 are mounted to the bottom of the base
panel 122.
[0043] Lens retainer strips 146 attach the lens panels 144 to the
outside faces of the enclosure to retain advertising or promotional
signage (not shown). Bottom foam panels 134 are placed atop the top
face of the bottom panel 122 and covered by moisture trays 136
including edges that resiliently engage adjacent inside faces of
the end wall, sidewall, and central divider panels. Cold cell
inserts 128b and 128c line the cavities in the enclosure. Sliding
lids 152a and 152b with handles 156 may cover the top of the
chiller in sliding arrangement in a frame 154. One or more
thermometers 160 with probes 162 are assembled in the chiller to
monitor temperatures inside the chiller.
[0044] The modular panel design and construction permits economical
production of a wide variety of incrementally-sized product
chillers. The blow-molded base panels 22, sidewall panels 24, and
end wall panels 26 may be incrementally sized and combined to
create an array of product chillers of varying sizes and
capacities. Other possible modular panel combinations are shown in
FIGS. 7 and 8. The embodiment of FIG. 7 is sized to receive
16-quart milk crates and includes a narrow base panel 222, a pair
of narrow end wall panels 226, and a pair of sidewall panels 124.
The sidewall panels 124 are the same sidewall panels used in the
larger chiller shown in FIGS. 5 and 6. In addition, one or more
narrow central divider panels 250 can be inserted to define
multiple chilled product cavities 227 in the server.
[0045] Another embodiment is shown in FIG. 8. A wide base panel 322
and pair of wide end wall panels 326 are assembled together with a
pair of sidewall panels 124. The same sidewall panels 124 used in
the embodiments shown in FIGS. 5 and 7 are included to form a
larger chiller with a larger capacity. As shown in FIG. 8A, central
divider panels 350 and central cold cells 360 may be used to divide
the server into multiple chilled product cavities 327. The
replaceable signage and moveable cover arrangements discussed above
may be adapted to any of these various server embodiments.
[0046] Production costs are minimized by using a minimum number of
costly production molds to blow-mold the bottom, end wall, and
sidewall panels in the desired incremental sizes. As illustrated in
FIGS. 10A and 10B, blow molds for each molded component may have
one or more removable mold sections 410 to permit panels of various
widths to be molded from a single mold assembly. For example, a
narrow end wall panel 402 can be produced from an end wall panel
mold including only two mold end sections 412 having parting line
X-X. A mold expansion section 410 may be inserted between the two
mold end sections to blow-mold a wider end wall panel 404 for a
wider chiller assembly. This same adjustable-mold production
process may be used for end wall panels, sidewall panels, base
panels, and/or central divider panels.
[0047] Production costs are further minimized by using a single
mold to produce both the end wall and central divider panels. As
shown in FIG. 11, a common panel 500 is molded to include a common
center portion 510, an end wall panel edge portion 520, and a
divider panel edge portion 530. For end wall panels, the divider
panel edge portion 530 is removed from the common panel to leave
only portions 510 and 520. Alternatively, to produce a divider
panel, the end wall panel edge portion 520, is removed from the
common panel. As best seen in FIG. 12, the resulting open end of
the hollow panel left by the parted edge portions 520 or 530
receives an insulating foam panel insert 30 and engages a tenon 80
on the base panel 22. As discussed above, the common panels and
resulting end wall and divider panels may be produced in various
incremental widths from a single mold assembly.
[0048] As will be apparent to those of ordinary skill in the art,
the invention can be adapted to various configurations of product
chillers and is not limited to the specific embodiments discussed
above. Those of ordinary skill in the art will also appreciate that
the invention could be carried out in other various forms, all of
which are deemed to be within the scope of the appended claims.
* * * * *