AU2010201470A1 - An Improved Merchandise Unit - Google Patents

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Invention Title: AN IMPROVED MERCHANDISE UNIT The following statement is a full description of this invention, including the best method of performing known to us: 2 FIELD OF THE INVENTION The invention relates to merchandiser units. More particularly, the invention relates to open faced, hot food merchandisers, such as pie warmers. BACKGROUND ART 5 [Mere reference to background art herein should not be construed as an admission that such art constitutes common general knowledge in relation to the invention.] Hot food merchandisers are used to promote the sale of heated foods such as pies, pastries, and sausage rolls. In particular, such merchandisers are used in quick service retail (QSR) locations, such as service stations. Such merchandisers vary in construction to suit 10 varied types of heating and hot holding technologies. Traditional designs are closed in, having a front door or panel, usually made of glass, which allows access to the food within. Newer designs feature an open front, allowing for quicker and unobstructed access to the food, and are therefore more suitable for self-serving applications. These designs rely on more sophisticated temperature control technology to 15 maintain a food-safe temperature in the product without overcooking or drying the products prematurely and therefore reducing the shelf life and quality of the product. In general, the additional effort in these new designs in justified by a comparative increase in product sales. Open face merchandisers typically have between three and six shelves, which are independently heated and temperature controlled, meaning each shelf has its own 20 temperature sensor. This is necessary because upper shelves experience an accumulative heat effect from rising heated air from the lower shelves. Unfortunately, this increases the complexity, cost, and size of open faced merchandisers. In some circumstances, the increased size of an open faced merchandiser means that it is not suitable to place the merchandiser in a high traffic point of sale (POS) location, potentially reducing sales. 25 It is an aim of this invention to provide an improved merchandiser which overcomes or ameliorates one or more of the disadvantages or problems described above, or which at least provides a useful alternative.

3 SUMMARY OF THE INVENTION According to a broad form of the invention, there is provided an open-faced merchandise unit for storing articles, and for maintaining the articles at a specified temperature or within a specified temperature range, the merchandiser comprising: 5 a controller; a plurality of temperature adjustable shelves that support and conduct heat to or absorb heat from the articles placed thereon, wherein the temperature adjustable shelves are electrically connected to the controller; and at least one sensor to provide feedback to the controller. 10 Preferably, the merchandiser will be utilised to store and maintain articles at a raised temperature, and the temperature adjustable shelves are adapted to provide heat to the articles. However, no limitation is meant thereby and the merchandiser could suitably be adapted to cool the articles and/or store them at a lowered temperature. It is to be understood that any reference to heating or cooling will generally also be applicable to the 15 other (where appropriate), and although the preferred form of the invention is to generally provide heating to articles, it will be appreciated that the invention could similarly be adapted to provide cooling to the articles. The articles are preferably food articles, but could also be beverages or other articles stored at non-room temperature. Typically, the articles will be heated food articles such as 20 pies, sausage rolls, pastries, meats, and other heated snacks or meals. Preferably, the shelves are attached to, or integral with, a portion of a back wall of the merchandiser. The shelves are preferably fixed to, or integral with, the back wall, but it will be appreciated that the shelves may only be fixed in use, and at least a portion may be removable for servicing and/or cleaning. 25 The shelves are preferably inclined or angled downwardly toward the forward or facing side of the merchandise unit to allow easier visual access and removal of the articles by a customer, as well as reducing the likelihood that the shelves will be touched during removal of articles. Preferably, the shelves are made from a material (or combination of materials) that conduct heat to the articles while remaining sanitary and resilient to 30 detergents. Even more preferably, the shelves are substantially made from metal or glass, but it will be appreciated any suitable material (or materials) may be utilised.

4 The shelves may be individually temperature adjustable, and provide heat (or cold) from within or beneath. Preferably, heat is provided by heating elements within the shelves. However, the heat (or cold) may be provided by any suitable means, and no limitation is meant thereby. For example, heat could be provided by electric elements, infra red 5 radiation, induction, gas, or the like. The heat transfer from the shelves to the articles according to the invention may comprise conduction, and convection, and/or radiation, but convection and radiative heat transfer are preferably minimised in favour of conductive heat transfer. The temperature of the shelves may preferably be set at any temperature in the range of between approximately 1 0 C and 99 0 C, but no limitation is meant thereby. 10 Each shelf may be individually controllable, so that articles may be stored or maintained at different temperatures on different shelves, or all of the shelves may be controlled simultaneously. The merchandise unit preferably also comprises two opposed side walls. The side walls preferably cover at least a substantial portion of the side of the merchandise unit, and 15 even more preferably, at least cover, and span, the sides of the shelves. The side walls may extend further than the sides of the merchandise unit, and/or beyond the length of the shelves. The side walls preferably minimise/reduce heat radiation and/or heat loss from the merchandiser unit. The side walls may be made of any suitable material (or combination of materials), but they are preferably substantially transparent to allow visual inspection of the 20 articles from the sides. For example, the side walls may be made substantially from glass or plastic, or from metal with glass or plastic panels or inserts. The merchandise unit may further comprise at least one service chamber for containing or holding components. The service chamber is typically located above or below the shelves, or both above and below. The service chamber preferably contains and 25 conceals at least a portion of the internal components of the merchandiser. The service chamber, particularly if located above the shelves, may include an audio and/or visual means such as an LCD panel (alternatively, an audio and/or visual means, such as an LCD screen, may be located elsewhere on the merchandiser). The audio/visual means may display/play information, advertisements or promotional material (if faced forwardly for 30 example), and/or instructions on how to use the merchandise unit (if faced rearwardly) or the like. The merchandiser may also include memory, and/or a card reader in connection with the audio/visual means to store content to be played.

5 The back wall of the merchandiser may comprise a hollow portion in communication with the chamber, wherein the hollow portion is adapted to receive cabling, electronics, structural supports, and the like. Preferably, the internal space defined by the hollow and the chamber(s) house a PCB regulator that accommodates the controller and 5 supplies power to the shelves as required. Preferably, the merchandiser further comprises one or more of the following: a mains switch, a power LED, nominal temperature gauge, and a display panel. The mains switch is preferably located on the back of the merchandise unit. Preferably, the interior of the merchandise unit is backlit to improve its appearance and prominence. Even more 10 preferably the merchandiser is backlit using two strips of LED backlights, typically provided for each shelf. Overall, the merchandise unit is preferably compact and/or requires only a small footprint to allow it to be positioned in high profile point of sale (POS) zones in stores. Furthermore, preferably the merchandise unit provides an improved ratio of articles (or 15 products) to occupied space, to increase the value of the merchandiser in a POS zone, retail 'red' zone, and/or for Quick Service Retail (QSR). Preferably at least the back wall of the unit has an access door accessible from the rear of the merchandiser to allow servicing, cleaning, and general access to the hollow portion and/or the chambers, (i.e. the interior of the back wall and merchandiser). 20 Preferably the overall structure of the merchandise unit, including the back wall, is made substantially from metal. The metal may be insulated to reduce heat losses from the merchandise unit, and or to prevent the exterior of the merchandiser, which may be contactable, from being at extreme temperatures. The controller may be any suitable controller, but is preferably a closed-loop 25 electronic control circuit. The controller typically receives feedback from the at least one sensor and controls power supplied to the temperature adjustable shelves. The at least one sensor is preferably a temperature sensor and, preferably there are less temperature sensors than there are temperature adjustable shelves. Preferably there are no more than half as many sensors as there are shelves (e.g. 1 30 sensor for 2 or 3 shelves, 2 sensors for 4 or 5 shelves, etc.). In preferred forms of the invention, only two strategically placed temperature sensors are provided for four or five 6 shelves. Additionally, other types of sensors may be utilised, including, for example, humidity sensor(s). The sensors may be read by the controller continually, periodically, or at suitable predetermined intervals as necessary to provide suitable control. In an embodiment having four shelves (referred to as shelves 1 to 4, with shelf 1 5 being the lowest shelf and shelf 4 being the highest shelf), two pairs of shelves are wired in parallel. Each pair of shelves may therefore essentially operate as a single controlled surface. In this embodiment, the lowest two shelves (shelves I and 2) are powered by the same control circuit, with the lowest shelf, shelf 1, being fitted with a temperature sensor (preferably a thermocouple). 10 A powered element, which is controlled to adjust the temperature of the shelves, is included within each shelf. In shelf 1, the element is preferably in direct contact with the underside of the shelf and operates with an expected accuracy of at least ±5*C and, more preferably, within ±20. In shelf 2, the element is preferably located adjacent the underside of the shelf, but not in direct contact. The element may be spaced a predetermined distance 15 from the underside such as, for example, I to 5mm from the underside and, preferably, between 1 to 2mm, or even more preferably, approximately 1.5mm above the underside. This distance from the underside of the shelf reduces an increase in temperature which can occur due to the shelf not being measured and/or controlled directly and/or individually. In particular, the temperature and/or rate of rise of the shelf is not altered significantly, but the 20 rate of rise in the core temperature of article(s) on the shelf is slowed due to transferring the heat via an air gap (i.e. the inherent inefficiency of indirectly heating the shelf via a relatively small air gap). The third shelf from the bottom, shelf 3, is fitted with a temperature sensor (preferably a thermocouple) like shelf 1. Again, the thermocouple is preferably in direct 25 contact with the underside of the shelf. Shelf 4 is spaced further from shelf 3 than it is from shelf 2 (and shelf 2 from shelf 1) due to design requirements. This increased spacing, together with an increase in air circulation around shelf 4, results in the element of shelf 4 not being spaced like that in shelf 2, but instead also being in direct contact with the underside of the shelf. As article(s) on the top shelf (shelf 4) are exposed to greater losses 30 due to air movement and/or the lack of a heated upper surface (e.g. from a shelf above), the direct contact of the element with the shelf compensates for the higher losses.

7 In this configuration, variations in shelf temperatures (particularly between controlled and uncontrolled shelves powered by the same control circuit) may result in only relatively small variations in the core temperature of the article(s). In particular, preferably the core temperature of articles on different shelves varies less than 5'C and, more 5 preferably, by no more than 2'C. The controller may apply power to the temperature adjustable shelves relative to a deviation in temperature from a target temperature. The applied power may be directly proportional, or may be applied according to a predetermined formula. The controller may comprise a P, PI, PID, or other suitable control algorithm. The controller may have a 1o limited amount of available power to apply across all of the temperature adjustable shelves, and preferably distributes power appropriately to the shelves to efficiently reach the target temperature. Preferably, the controller can maintain an effective temperature range of 14 'C nominally across all of the shelves. Even more preferably, the controller can maintain the temperature of five temperature adjustable shelves within 14 *C of the target 15 temperature with feedback from only two strategically located temperature sensors. Preferably, the controller utilises a 2 channel control system whereby each channel is controlled by a different set of algorithms to achieve an acceptable temperature range across the shelves. The shelves may be controlled so as to not exceed an optimum internal temperature 20 of a particular article or articles placed on the shelf. This may assist in the control of moisture content within an article without the provision of a humidity control system. The optimum internal temperature of an article may be determined according to the type of heating required. For example, if only maintenance of heat is required, then the maximum temperature of the shelf may not exceed a preset maximum temperature which is equal to 25 an internal temperature of the article. This means that once a food article is placed on the shelf, the item is not further cooked. A similar condition occurs if the article is to be defrosted, heated, and then its temperature maintained. The shelf may be heated to a defrosting/heating temperature to heat the article, but once the temperature of the article reaches a preset optimum 30 temperature for that particular article, the temperature does not rise above the internal temperature of that article when cooked.

8 Preferably, the ratios of shelves, enclosed areas, open areas, together with the accumulative heat effect through the rising of heated air from lower shelves is compensated with different articles sizes and, more particularly, different surface to volume ratios between articles. Additionally, preferably the combination of shelf material, shelf mass, 5 applied electrical energy, and heat transfer (radiant, convective, and conductive) achieve a minimised and more efficient temperature range between the shelves, and heated elements therein, and the articles. According to another broad form of the invention, there may be provided a method of storing articles and maintaining the articles at a specified temperature, or within a 10 specified temperature range, within a merchandiser, the method comprising the steps of: reading the temperature of at least one of a plurality of temperature adjustable shelves that support and conduct heat or cold to the articles, and controlling the power supplied to all of the temperature adjustable shelves. The step of controlling the power supplied to all of the temperature adjustable 15 shelves may comprise controlling the power supplied to more than one set of shelves. For example, in a merchandiser with four shelves, the step of controlling power supplied to all of the temperature adjustable shelves may comprise controlling two sets of two shelves individually. Preferably each set of shelves comprises a temperature sensor configured to read the temperature of at least one shelf in the set. 20 In order that the invention may be more readily understood and put into practice, one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 illustrates a perspective view of a five shelf merchandiser according to an 25 embodiment of the invention. Figure 2 illustrates a side elevation view of a five shelf merchandiser according to an embodiment of the invention. Figure 3 illustrates a front elevation view of a five shelf merchandiser according to an embodiment of the invention.

9 Figure 4 illustrates a perspective cutaway view of a five shelf merchandiser according to an embodiment of the invention. Figure 5 illustrates a perspective cutaway view of an upper portion of a merchandiser according to an embodiment of the invention. 5 Figure 6 illustrates a perspective view of an upper portion of a merchandiser according to an embodiment of the invention. Figure 7 illustrates a perspective view of a three shelf merchandiser according to an embodiment of the invention. Figure 8 illustrates a perspective view of a two shelf merchandiser according to an 10 embodiment of the invention. Figure 9 illustrates a perspective view of a two shelf merchandiser according to an embodiment of the invention. Figure 10 illustrates a perspective view of a three shelf merchandiser according to an embodiment of the invention. 15 DESCRIPTION OF PREFERRED EMBODIMENTS Figure 1 illustrates a merchandiser 10, having five shelves 11 extending from a back wall portion 12. The merchandiser 10 also has transparent side walls 13 that cover the sides of the merchandiser 10 and the shelves 11. The transparent side walls 13 are preferably made of glass or Perspex, but it will be envisaged that other materials may be 20 utilised, and/or that the side walls 13 may be opaque. The merchandiser 10 also has an upper portion 14 that houses an LCD screen 15 capable of displaying text, images, animations, videos, and the like. Near the rear of the upper portion 14 is a grill or vent 16 that provides ventilation to the interior of the merchandiser. The merchandiser 10 also has a lower base portion 17 that not only provides 25 the merchandiser with a solid base to rest on a surface, but also has an LED temperature display 18. The shelves 11, have a heating element (not shown), preferably coiled, inside them to conduct heat to articles placed on the shelves. As clearly illustrated in figure 2, the 10 shelves 11 are angled or inclined to allow easy visual inspection of the articles contained thereon from above. As illustrated in figure 4, the merchandiser 10 has various parts located internally out of sight. In a hollow in the back wall portion 12 are two strips of LED backlights 19 5 utilised to light the merchandiser. A transformer 20 is also located internally, to step down 240V AC mains power to 12V DC power. A PCB 21 is provided, containing control circuitry to determine suitable power to be applied to each shelf to achieve or maintain a particular temperature, or range of temperatures. Two temperature sensors (not shown) are provided at, in, or near two of the shelves to provide feedback to the control circuitry. 10 Preferably, at least one of these temperature sensors is placed at, in, or near the second shelf from the bottom. As also illustrated in figure 5, the upper portion houses a card reader 22 for reading a memory card 23, such as a mini SD card, and IR control 24. Illustrated in figures 5 and 6, an access cover 25 is provided on the top of the merchandiser to provide access to the 15 memory card 23. This is particularly useful to change the data stored on the memory card, which may consequently change the content displayed on the LCD 15. The access cover 25 is secured in place by an access screw 26, which is preferably an M4 screw. A button 27 is provided on the top of the merchandiser 10, which can be used for any suitable purpose but, preferably, is utilised as an LCD trigger button to enable/disable 20 the LCD and/or change the content being displayed. The merchandiser 10 may be any suitable size, but is preferably sized suitably to sit on a bench top or counter. Approximately 200 to 400mm deep, 150mm to 400mm wide, and 400 to 800mm high have been found to be suitable sizes for the embodiment illustrated in figures 1 to 6, but no limitation is meant thereby. 25 Illustrated in figures 7 to 10 are different shaped merchandisers with different numbers of shelves. Where there are less shelves there may accordingly be less sensors. Preferably, there are less sensors than shelves. For example, in the embodiment illustrated in figure 8, only one sensor may be required for the two shelves. It is to be understood that the terminology employed above is for the purpose of 30 description and should not be regarded as limiting.

II The foregoing embodiments are intended to be illustrative of the invention, without limiting the scope thereof. The invention is capable of being practised with various modifications and additions as will readily occur to those skilled in the art.

Claims (19)

1. 2. An open faced merchandiser according to claim 1, wherein at least one sensor comprises a temperature sensor.
2. 3. An open faced merchandiser according to claim 2, wherein the temperature sensor comprises a thermocouple.
3. 4. An open faced merchandiser according to claim 2 or 3, wherein the temperature sensor is located within a shelf.
4. 5. An open faced merchandiser according to any one of claims 2 to 4, wherein there are less temperature sensors than there are shelves.
5. 6. An open faced merchandiser according to claim 5, wherein there are no more than half as many temperature sensors as there are shelves.
6. 7. An open faced merchandiser according to any one of the preceding claims, further comprising an audio and/or visual means.
7. 8. An open faced merchandiser according to claim 7, wherein the audio and/or visual means plays advertising material.
8. 9. An open faced merchandiser according to claim 7 or claim 8, wherein the audio and/or visual means comprises an LCD Panel. 13
9. 10. An open faced merchandiser according to any one of the preceding claims, further comprising a back wall and opposed side walls respectively adjacent the back and sides of the shelves.
10. 11. An open faced merchandiser according to any one of the preceding claims, wherein the shelves are angled downward.
11. 12. An open faced merchandiser according to any one of the preceding claims, wherein each shelf further comprises a heating element.
12. 13. An open faced merchandiser according to claim 12, wherein the heating element is in direct contact with a portion of at least one shelf, and is not in direct contact with at least one shelf.
13. 14. An open faced merchandiser according to any one of the preceding claims, wherein pairs of shelves having a single sensor are controlled simultaneously.
14. 15. An open faced merchandiser according to any one of the preceding claims, wherein the article is a food article.
15. 16. A method of storing articles and maintaining the articles at a specified temperature, or within a specified temperature range, within a merchandiser, the method comprising the steps of: reading the temperature of at least one of a plurality of temperature adjustable shelves that support and conduct heat or cold to the articles, and controlling the power supplied to all of the temperature adjustable shelves.
16. 17. A method according to claim 16, wherein the step of controlling the power supplied to all of the temperature adjustable shelves comprises controlling the power supplied to more than one set of shelves.
17. 18. A method according to claim 17, wherein each set of shelves comprises a temperature sensor configured to read the temperature of at least one shelf in the set.
18. 19. An open faced merchandiser for storing articles and for maintaining the articles at a specified temperature or within a specified temperature range, the merchandiser being substantially as hereinbefore described with reference to the accompanying drawings. 14
19. 20. A method of storing articles and maintaining the articles at a specified temperature, or within a specified temperature range, within a merchandiser, the method being substantially as hereinbefore described with reference to the accompanying drawings.