Abstract:
A modular rack assembly for storing goods includes a first rack having a base and a plurality of wall portions extending away from the base. Each of the plurality of wall portions is separated from an adjacent of the plurality of wall portions by a space. A lip extends around a perimeter of the base. A second rack is generally identical to the first rack such that, in a first position, the second rack is stackable on top of the first rack such that the first rack engages the base of the second rack in a plane, and the lip of the second rack extends within the plane. A method of transferring heat between atmosphere and chub logs on the rack assembly includes the steps of loading chub logs onto a first rack and then placing a second rack on top of the first rack.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to a modular rack assembly for storing food products to enhance the freezing process.  
       BACKGROUND OF THE INVENTION  
       [0002]     Chub is a processed meat product that is formed into logs for sale. To lengthen the life of the chub and to aid in transport to a sales destination, the chub is frozen after manufacturing. Prior to freezing, the chub is typically inserted into boxes, with two chub logs per box. The boxes are stacked onto a pallet and then transported into a freezer. However, due to the volume of chub that is densely packed onto the pallet, as well as the insulating properties of the boxes, it can take up to three days for the chub to fully freeze.  
         [0003]     It would be beneficial to be able to stack the chub in a manner that would decrease the freezing time. Further, it would be beneficial to provide a modular system for stacking the chub that can be rearranged to form a smaller volume when the chub is not stacked in the system.  
       SUMMARY OF THE INVENTION  
       [0004]     Briefly, a modular rack assembly for storing goods is provided. The rack assembly comprises a first rack having a base and a plurality of wall portions extending upwardly away from the base. Each of the plurality of wall portions is separated from an adjacent portion of the plurality of wall portions by a relatively flat region. A lip extends around a perimeter of the base. A second rack is generally identical to the first rack. In a first position, the second rack is stackable on top of the first rack such that the first rack engages the base of the second rack in a region of contact defining a plane, and the lip of the second rack extends across the plane.  
         [0005]     Further, the present invention provides a modular rack assembly for storing goods. The assembly comprises a first rack having a base and a plurality of wall portions extending upwardly away from the base. Each of the plurality of wall portions is separated from an adjacent portion of the plurality of wall portions by a relatively flat region. A lip extends around a perimeter of the base. A second rack is generally identical to the first rack. In a first position, the second rack is stackable on top of the first rack such that the first rack engages the lip of the second rack.  
         [0006]     Additionally, the present invention provides a modular rack assembly for storing goods. The assembly comprises a first rack having a base and a plurality of wall portions extending upwardly away from the base. Each of the plurality of wall portions is separated from an adjacent of the plurality of wall portions by a relatively flat region. Each of the plurality of wall portions includes convex tops. A second rack is generally identical to the first rack. In a first position, the second rack is stackable on top of the first rack such that the convex tops of the first rack engage the base of the second rack.  
         [0007]     The present invention also provides a modular rack assembly comprising a first rack having a base and a plurality of wall portions extending upwardly away from the base. Each of the plurality of wall portions is separated from an adjacent portion of the plurality of wall portions by a relatively flat region and wherein each of the plurality of wall portions is tapered from wider at the base to narrower in a direction away from the base. The rack also includes a front end, a rear end, and a plurality of spacer portions extending away from the base between the front end and the rear end. The plurality of spacer portions extend perpendicularly to at least one of the plurality of wall portions. A plurality of concave portions extend between the front end and the rear end and bounded by one or more of the plurality of spacer portions. A lip extends around a perimeter of the base. A second rack is identical to the first rack. In a first position, the second rack is stackable on top of the first rack such that the first rack engages the base of the second rack in region of contact extending in a plane, and the lip of the second rack extends across the plane. Further, the first rack comprises first indicia on at least one of its plurality of wall portions and the second rack comprises second indicia on at least one of its plurality of wall portions such that, in the first position, only one of the first and second indicia is visible from any one direction and, in the second position, both of the first and the second indicia are visible from any one direction.  
         [0008]     Also, the present invention provides a method of transferring heat between a product and a surrounding atmosphere comprising the steps of providing a first rack having a base and a plurality of wall portions extending upwardly away from the base. Each of the plurality of wall portions is separated from an adjacent of the plurality of wall portions by a relatively flat region. The first rack also includes a front end, a rear end, a plurality of spacer portions extending away from the base between the front end and the rear end, a plurality of concave portions extending between the front end and the rear end and bounded by one or more of the plurality of spacer portions, and a lip extending around a perimeter of the base. The method further includes the step of loading the plurality of chub logs individually in the plurality of concave regions; placing a second rack, identical to the first rack, on top of the first rack such that the first rack engages the base of the second rack in a region of contact, forming a space between the base of the second rack and the chub logs; and exposing the product to the surrounding atmosphere to transfer heat between the chub logs and the surrounding atmosphere. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]     The foregoing summary, as well as the following detailed description of a desired embodiment of the invention, will be better understood when read in conjunction with the appended drawings, which are incorporated herein and constitute part of this specification. For the purposes of illustrating the invention, there are shown in the drawings embodiments that are presently desired. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings, the same reference numerals are employed for designating the same elements throughout the several figures. In the drawings:  
         [0010]      FIG. 1  is a perspective view of a rack assembly according to a first embodiment of the present invention, with the rack assembly in a stacked position and product stacked within the assembly.  
         [0011]      FIG. 2  is a perspective view of the rack assembly of  FIG. 1 , with the product removed and the rack assembly in a nested position.  
         [0012]      FIG. 3  is a sectional view of the rack assembly of  FIG. 1 .  
         [0013]      FIG. 4  is a sectional view of the rack assembly of  FIG. 2 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0014]     Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. The terminology includes the words specifically mentioned, derivatives thereof and words of similar import. The following describes desired embodiments of the invention. However, it should be understood based on this disclosure, that the invention is not limited by the desired embodiments of the invention.  
         [0015]     Referring generally to the figures, several embodiments of a rack assembly for storing a freezing processed meat product, such as chub, are shown. The rack assembly includes a plurality of racks that are each used to store several rolls of chub. In a “use” configuration, the racks are stackable on each other with a volume in between each rack in which chub is stored. In a “storage” configuration, without chub, the racks are able to be nested in each other, generally reducing the volume of the stacked racks and allowing for easier storage and transfer of the racks.  
         [0016]     Referring to  FIGS. 1-4 , a first embodiment of a modular rack assembly  100  is shown. The rack assembly  100  includes a first rack  110  and a second rack  210 . While only two racks  110 ,  210  are disclosed, more than two racks may be used within the spirit and scope of the present invention.  
         [0017]     Preferably, the first rack  110  and the second rack  210  are structurally identical. As described herein, the reference numerals for the second rack  210  are the same as for first rack  110  for corresponding elements of the racks  110 ,  210 . As can be seen in  FIGS. 1 and 3 , when the second rack  210  is stacked on top of the first rack  110  in a first, or stacked, position, a volume  102  is formed between the first rack  110  and the second rack  210  such that a plurality of rolls of chub  104  may be stored within the volume  102 . As seen in  FIGS. 2 and 4 , when the second rack  210  is placed on top of the first rack  110  in a second, or nested, position, the first rack  110  is able to nest in the second rack  210 , greatly reducing the volume  102  between the first rack  110  and the second rack  210 .  
         [0018]     While the intended product to be stored on the racks  110 ,  210  is rolls of chub  104 , those of ordinary skill in the art will recognize that other products may be stored on the racks  110 ,  210  as well. As can be seen from  FIG. 1 , in a preferred embodiment, five rolls of chub  104  are able to be stored in the volume  102 .  
         [0019]     Referring now to  FIG. 3 , the rack  110  has a base  112  that extends in a first plane  113 . The base  112  is generally rectangular in shape, with a first dimension being longer than a second orthogonal dimension. To provide a point of reference, along the longer dimension, one side of the base  112  (visible in  FIG. 1 ) is called the front end  112   a  and an opposing side of the base  112  (not visible in  FIG. 1 ) is called the rear end  112   b . The perimeter of the base  112  includes a lip  115  that extends downward from the base  112 .  
         [0020]     A plurality of wall portions  114  extends along the perimeter of the base  112  and upward from the base  112 . Each of the plurality of wall portions  114  is separated from an adjacent of the plurality of wall portions  114  by a relatively flat region  116 . Each of the plurality of wall portions  114  is tapered from wider at the base  112  to narrower in a direction away from the base  112 . Further, each of the plurality of wall portions  114  preferably includes curved corners and edges, both where each wall portion  114  engages the base  112  and also where each wall portion  114  extends away from the base  112 . The corners are curved to reduce stress on the rack  110  and to reduce the possibility of cracking.  
         [0021]     A plurality of spacer portions  120  extend from the base  112  between the front end  112   a  and the rear end  112   b . Each of the plurality of spacer portions  120  is bounded on at least one side by a relatively flat region  121 . The plurality of spacer portions  120  extend perpendicularly to the wall portions  114  that extend along each of the front end  112   a  and the rear end  112   b . Each of the plurality of spacer portions  120  is tapered from wider at the base  112  to narrower in a direction away from the base  112 . Further, each of the plurality of spacer portions  120  preferably includes curved corners and edges, both where each spacer portion  120  engages the base  112  and also where each spacer portion  120  extends away from the base  112 . The corners and edges are curved to reduce stress on the rack  112  and to reduce the possibility of cracking. The curves at the tops of the wall portions  114  and the spacer portions  120  are convex in shape to facilitate the stacking of the rack  210  on top of the rack  110  during use.  
         [0022]     The spacer portions  120  cooperate with the wall portions  114  that extend between the front end  112   a  and the rear end  112   b  to form concave channels  122 . The concave channels  122  are each bounded by at least one spacer portion  120 . Each channel  122  is sized to receive a roll of chub  104 . When inserted into each channel  122 , the chub  104  extends longitudinally between the front end  112   a  and the rear end  112   b . The heights of the wall portions  114  and the spacer portions  120  are higher than that of the chub  104  that is inserted into the racks  110 ,  210   
         [0023]     The sectional views of the racks  110 ,  210 , shown in  FIGS. 3 and 4 , show that each of the wall portions  114  includes a cavity  124  formed therein. Each cavity  124  is sized and shaped to receive a substantial portion of a wall portion  114  from a similarly shaped rack. Similarly, each of the spacer portions  120  includes a cavity  126  formed therein. Each cavity  126  is sized and shaped to receive a substantial portion of a spacer portion  120  from a similarly shaped rack.  
         [0024]     Referring to  FIGS. 1 and 3 , a vertical axis  118  extends from a geometric center of the first rack  110 . When the second rack  210  is placed on top of the first rack  110 , in either the first position or the second position, the vertical axis  118  extends through the geometric center of the second rack  210  as well. The assembly  100  is movable between the first position and the second position by rotating one of first rack  110  and the second rack  210  180 degrees about the vertical axis  118 .  
         [0025]     When in the first position, as shown in  FIGS. 1 and 3 , the base  112  of the second rack  210  is supported by the tops of the wall portions  114  and the spacer portions  120 . The wall portions  114  and the spacer portions  120  engage the base  112  in a contact plane, with the lip  115  of the second rack  210  extending across the contact plane. Further, the tops of the wall portions  114  on the first rack  110  engage and interlock with the lip  115  of the second rack  210  to prevent the second rack  210  from sliding laterally off the first rack  110 .  
         [0026]     The racks  110 ,  210  are asymmetrical about a lateral plane that encompasses the vertical axis  118 . The plane extends out of the plane of the paper of  FIG. 3 . The asymmetrical arrangement allows the base  112  of the second rack  210  to rest on the tops of the wall portions  114  and the spacer portions  120  when the first and second racks  110 ,  210  are in the first position. To support this asymmetrical arrangement, an odd number of rolls of chub  104  are able to be stored within each rack  110 ,  210 .  
         [0027]     Optionally, as shown in  FIGS. 1 and 2 , indicia  140  may be used to assist a user in quickly determining whether the second rack  210  is being placed on top of the first rack  110  in the proper position. The exemplary indicia  140  is in the form of a horizontal stripe located along at least one of the wall portions  114 . When the first and second racks  110 ,  210  are in the first position, as shown in  FIG. 1 , the indicia  140  is visible only on the front end  112   a  of rack  110 , and not on rear end  112   b  of rack  210 , which is located directly over front end  112   a  of first rack  110 . When the first and second racks  110 ,  210  are in the second position, as shown in  FIG. 2 , the indicia  140  is visible on the front end  112   a  of the first rack  110  and the front end  112   a  of the second rack  120 , which is located directly over the front end  112   a  of first rack  110 .  
         [0028]     Optionally, although not shown, the wall portions  114  may include vertical corrugation to increase the vertical strength of each rack  110 ,  210 . Preferably, the racks  110 ,  210 , are constructed from a material that is not brittle and can maintain its integrity over a large number of thermal cycles. Such a material is a rubberized polyethylene, although an artisan will recognize that other suitable materials, including, but not limited to polycarbonate, polyester, polystyrene, polypropylene, ABS, or other suitable polymer resin material, may be used as well.  
         [0029]     For health reasons, it is important that the racks  110 ,  210  not have any holes therein. After use, the racks  110 ,  210  are sanitized prior to reuse. Holes in the racks may allow water used during sanitization to adhere to the side walls of the holes, allowing bacteria to grow and forming a health hazard.  
         [0030]     In use in a manufacturing plant (not shown), logs of chub  104  are placed in the first rack  110  such that the chub  104  extends between the front end  112   a  and the rear end  112   b . In the present embodiment, up to five logs of chub  104  may be placed in the first rack  110 . Similarly, up to five logs of chub  104  are placed in the second rack  210 . The first rack  110  is placed on a pallet (not shown). The second rack  210  is placed on top of the first rack  110  such that the indicia  140  on only one of the first and second racks  110 ,  210  is visible from either the front end  112   a  and the rear end  112   b . In this manner, the wall portions  114  and spacer portions  120  of the first rack  110  engage the bottom of the base  112  of the second rack  210  and support the second rack  210 . The second rack  210  does not engage or press upon the chub  104  in the first rack  110 . Additional racks (not shown) may be stacked upon the second rack  210  in a similar fashion, until a desired number of racks are stacked upon each other.  
         [0031]     The pallet with the racks is then transported to a freezer, where the chub  104  is frozen. The configuration of the racks  110 ,  210  allows cold air to pass through the relatively flat region s  116  to flow between the racks  110 ,  210 . Since the chub  104  in the first rack  110  does not support the second rack  210 , the air can flow between the top of the chub  104  in the first rack  110  and the bottom of the base  112  of the second rack  210 , enhancing the freezing process of the chub  104 .  
         [0032]     After the chub  104  is frozen, the pallet with the chub  104  is removed from the freezer and shipped to a sales destination, where the chub  104  is removed from the racks  110 ,  210  for sale. After all of the chub  104  is removed from the racks  110 ,  210 , the racks can be sanitized according to known techniques. After sanitation, the racks  110 ,  210  are nested in the second position for transport back to the manufacturing plant. The nesting position is formed by rotating the second rack  210  180 degrees about the vertical axis  118  relative to the stacked position.  
         [0033]     The first rack  110  is place on the pallet and the second rack  210  is placed on top of the first rack  110  such that the indicia  140  on both racks  110 ,  210  is visible from either the front end  112   a  or the second end  112   b . The wall portions  114  of the first rack  110  fit into the cavities  124  of the second rack  210  and the spacer portions  120  of the first rack  110  fit into the cavities  126  of the second rack  210 , as shown in  FIG. 4 . The volume  102  between the first rack  110  and the second rack  210  is substantially reduced, reducing shipping volume of the rack assembly  100  and decreasing shipping costs to return the rack assembly  100  back to the manufacturing plant.  
         [0034]     Although the invention is illustrated and described herein with reference to a specific embodiment, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention. While a preferred embodiment of the invention has been shown and described herein, it will be understood that such embodiment is provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.  
         [0035]     What is claimed: