Method for operating a temperature controlled delivery box

A temperature controlled delivery appliance and a method of operating the same are provided. The temperature controlled delivery appliance includes a storage container, a climate control system for regulating the temperature within the storage container, and a controller for implementing a pre-conditioning method, which includes maintaining the storage container at a preconditioning temperature until a delivery notification is received, and operating the climate control system to regulate the container temperature to a target temperature upon receiving the delivery notification.

FIELD OF THE INVENTION

The present subject matter relates generally to temperature controlled delivery boxes, and more particularly, to methods for operating temperature controlled delivery boxes.

BACKGROUND OF THE INVENTION

Given the rise in food and grocery delivery services, temperature controlled and access secure delivery appliances are desirable to permit deliveries when the consumer is not home. For example, delivery appliances are typically positioned outdoors of a residence and have a climate control system for regulating the temperature within a storage container positioned within a cabinet of the delivery appliance. In this manner, the consumer may receive delivery of food orders and maintain that food at the desired storage temperature, even while not at home. For example, the user or the delivery service may set a temperature of the delivery appliance at a desired temperature to avoid spoiling perishable food items or to otherwise prevent degradation of the quality of the food which might otherwise occur if the food were stored in an uncontrolled environment.

Notably, consistently maintaining the delivery appliance at the desired temperatures can expend large amounts of energy and result in additional wear on the heating and cooling components. For example, it may be difficult or costly to maintain the storage container at refrigerator temperatures (e.g., approximately 37° F.) or at freezer temperatures (e.g., approximately 0° F.) regardless of the outside temperature. Therefore, it may be desirable to heat or cool the storage container to the desired temperature only when food is expected for delivery. However, it is often inefficient to quickly heat or cool an unregulated container to a significantly different desired temperature. In addition, the heating or cooling systems may be incapable of regulating the temperature as quickly as needed, particularly if there is a large difference between the actual and target temperature.

Accordingly, a temperature controlled delivery box and methods of controlling the same for improved operation would be desirable. More specifically, a method for regulating the temperature of a delivery box quickly, efficiently, and without significant appliance degradation would be particularly beneficial.

BRIEF DESCRIPTION OF THE INVENTION

In one exemplary embodiment, a method for pre-conditioning a temperature controlled delivery appliance is provided. The temperature controlled delivery appliance includes a storage container and a climate control system. The method includes maintaining the storage container at a preconditioning temperature, receiving a delivery notification, obtaining a target temperature, and operating the climate control system to regulate a container temperature to the target temperature.

In another exemplary embodiment, a temperature controlled delivery appliance is provided, including a cabinet, a storage container positioned within the cabinet for receiving delivered items for storage, and a climate control system in thermal communication with the storage container for regulating a temperature of the storage container. A controller is operably coupled to the climate control system for maintaining the storage container at a preconditioning temperature, receiving a delivery notification, obtaining a target temperature, and operating the climate control system to regulate a container temperature to the target temperature.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 through 4depict a temperature controlled delivery appliance10that is generally configured for receiving delivery of food items or other articles that are preferably stored in a temperature controlled environment. According to exemplary embodiments, temperature controlled delivery appliance10is positioned outside a consumer's residence and is configured for receiving grocery or other food deliveries. It should be appreciated that the term “temperature controlled delivery appliance,” or simply “delivery appliance,” is used in a generic sense herein to encompass any device intended for storing items in a refrigerated, heated, or other climate controlled environment. In addition, it should be understood that the present subject matter is not limited to use in delivery appliances. Thus, the present subject matter may be used for any other suitable purpose, such as for receiving any other product or item that is desirably maintained in a temperature controlled environment.

In the illustrated example embodiment shown inFIG. 1, the temperature controlled delivery appliance10includes a casing or cabinet12that extends between a top and a bottom along a vertical direction V, between a first side and a second side along a lateral direction L, and between a front side and a rear side along a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular to one another, such that an orthogonal coordinate system is generally defined.

As illustrated delivery appliance10includes one or more storage containers14mounted within cabinet12. Specifically, according to the illustrated embodiment, delivery appliance10includes three storage containers14mounted in or suspended from a top panel16of cabinet12, e.g., using any suitable support brackets, mechanical fasteners, welding, snap-fit mechanisms, etc. In addition, it should be appreciated that an insulating material (not shown), such as foam panels, fiberglass, or spray-in foam insulation, may be positioned within cabinet12around storage containers14to provide thermal and/or sound insulation to delivery appliance10.

As illustrated, each of the three storage containers14define an opening18at top panel16of cabinet12. In this regard, food items20(FIG. 3) or other temperature controlled products may be positioned within storage containers14for temperature controlled storage, e.g., until they may be moved to a refrigerator appliance or pantry when the consumer returns home. As explained in detail below, each storage container14may be maintained at a different temperature for receiving foods that have different desired storage temperatures. For example, as illustrated inFIG. 3, storage containers14may have target temperatures suitable for storing room temperature food items20(such as bread, cereal, etc.), refrigerator food items (e.g., fruits, vegetables, milk, etc.), and frozen food items20(e.g., frozen pizza, ice cream, etc.).

Although the figures illustrate delivery appliance10as including three storage containers14having substantially rectangular cross sections and being spaced apart along the lateral direction L, it should be appreciated that the illustrated embodiment is used only as an example. According to alternative embodiments, delivery appliance10may include any suitable number of storage containers14having any suitable shape, size, and configuration. In addition, aspects of the present subject matter may apply to conventional refrigerator appliance with doors pivotally mounted to a front of the appliance. Such embodiments are contemplated as within the scope of the present subject matter.

Delivery appliance10further includes a door30rotatably attached to cabinet12in order to permit selective access to storage containers14. Specifically, as illustrated, door30is pivotally mounted to a back of cabinet12and is positioned over openings18in the closed position. A handle32is mounted to or defined in door30to assist a user with opening and closing door30and a latch assembly34is mounted to cabinet12and/or door30for selectively locking door30in the closed position. Latch assembly34may be desirable, for example, to ensure only secured access (e.g., via the consumer or delivery person) and to prevent tampering or theft after food items20are delivered.

Referring now generally toFIGS. 2 through 4, delivery appliance10further includes a drainage system40for collecting and discharging liquids from within storage containers14, e.g., such as melted items, condensation, melted frost, etc. Specifically, a drain42is defined in a bottom of each storage container14. Drain42may be in fluid communication with one or more drainage pipes44for routing liquid out of storage containers14under the force of gravity. The drainage pipes44may merge and pass all collected liquid through a mechanical compartment46(FIG. 2) where it may be discharged from delivery appliance10(e.g., to an external drain) or used for other purposes within delivery appliance10. Although drainage system40is illustrated as a gravity operated system, it should be appreciated that a suitable drainage pump may be used according to alternative embodiments.

Referring now specifically toFIGS. 2 and 5, mechanical compartment46may be defined in a rear wall of cabinet12and may be configured for receiving various operating components of delivery appliance10. For example, delivery appliance10may include a climate control system50that includes various components for regulating one or more container temperatures, e.g., the temperature measured within respective storage containers14. Thus, climate control system50may generally be in thermal communication with storage containers14and some or all components of climate control system50may be mounted within mechanical compartment46.

Referring now specifically toFIG. 5, a schematic view of certain components of temperature controlled delivery appliance10and climate control system50will be illustrated and described according to an exemplary embodiment. As described below, climate control system50may generally include a system or devices for heating storage containers14and/or a system or devices for cooling storage containers14. Although an exemplary climate control system50is described below, it should be appreciated that climate control system50may include different component, configuration, and subsystems for heating, cooling, humidifying, dehumidifying, or otherwise controlling the climate with each of the respective storage containers14.

According to exemplary embodiments, it may sometimes be desirable to raise the container temperature within one or more storage containers14, e.g., when it is very cold outside or if hot food items20are being stored. In such cases, delivery appliance10may include a heating device52in thermal communication with one or more storage containers14for regulating the temperature of the storage containers14. Thus, heating device52may be selectively activated and deactivated to control the container temperature. In general, heating device52may be any suitable type of heating element, such as an electric resistance heating element. In addition, heating device52may be used periodically to melt any frost build-up within storage containers14.

In addition, it may frequently be desirable to lower the container temperature of one or more storage containers14, e.g., when is it relatively warm outside or when chilled or perishable food items20are stored. In this regard, delivery appliance10may include features to operate delivery appliance as a refrigerator and/or freezer appliance. For example, delivery appliance10may include a sealed refrigeration system or sealed system60, which is generally configured for executing a vapor compression cycle for cooling storage containers14, as explained below.

In this regard, for example, sealed system60may include a compressor64, a condenser66, an expansion device68, and one or more evaporators70connected in series by fluid conduit72that is charged with a refrigerant. As will be understood by those skilled in the art, sealed system60may include additional components, e.g., at least one additional evaporator, compressor, expansion device, and/or condenser. As an example, sealed system60may include three evaporators wrapped directly around storage containers14.

Within sealed system60, refrigerant flows into compressor64, which operates to increase the pressure of the refrigerant. This compression of the refrigerant raises its temperature, which is lowered by passing the refrigerant through condenser66. Within condenser66, heat exchange with ambient air takes place so as to cool the refrigerant. A fan74may be used to pull air across condenser66, as illustrated by arrows inFIG. 5, so as to provide forced convection for a more rapid and efficient heat exchange between the refrigerant within condenser66and the ambient air. Thus, as will be understood by those skilled in the art, increasing air flow across condenser66can, e.g., increase the efficiency of condenser66by improving cooling of the refrigerant contained therein.

An expansion device68(e.g., a electronic expansion valve, capillary tube, or other restriction device) receives refrigerant from condenser66. From expansion device68, the refrigerant enters evaporator70. Upon exiting expansion device68and entering evaporator70, the refrigerant drops in pressure. Due to the pressure drop and/or phase change of the refrigerant, evaporator70is cool relative to storage containers14of delivery appliance10. As such, by wrapping evaporators70around storage containers14or positioning evaporator70coils within the walls of the storage containers14, the temperature within storage containers14may be lowered.

Notably, as illustrated inFIG. 5, delivery appliance10may include three storage containers14, each of which may have a dedicated evaporator70. According to an exemplary embodiment, a single compressor64, condenser66, and expansion device68may support the operation of such evaporators70. In this regard, sealed system60may include a refrigerant control valve76for regulating the flow of refrigerant to evaporators70to provide selective and independent cooling of each storage container14. In this manner, using climate control system50, each storage container14may have a different pre-conditioning temperature or target temperature, as described in more detail below. It should be appreciated that more or fewer storage containers14may be used and the configuration of one or more evaporators70may vary while remaining within the scope of the present subject matter.

The sealed system60depicted inFIG. 5is provided by way of example only. Thus, it is within the scope of the present subject matter for other configurations of the refrigeration system to be used as well. For example, according to alternative embodiments, cooled air may be passed over evaporator70and into storage containers14instead of relying on contact cooling. In addition, although sealed system60is described above as performing a vapor compression cycle to refrigerate storage containers14, it should be appreciated that a sealed system may be alternately operated as a heat pump, e.g., and thus perform a heat pump cycle for heating storage containers14. In this regard, for example, sealed system60may include a four-way reversing valve which could also be used to reverse the flow of refrigerant within fluid conduit72such that condenser66operates as an evaporator, and evaporator70operates as a condenser.

In some embodiments, delivery appliance10also includes one or more sensors that may be used to facilitate improved operation of delivery appliance10, such as described below. For example, in order to obtain temperature or humidity data, delivery appliance10may include a plurality of temperature sensors and/or humidity sensors. Specifically, as shown inFIG. 3, a container temperature sensor80may be positioned within or placed in thermal communication with each storage container14for measuring a container temperature therein. For example, according to the illustrated embodiment, container temperature sensors80are mounted to a rear wall of each storage container14. Alternatively, container temperature sensors80may be positioned at any other suitable location proximate to storage containers14for providing data indicative of the container temperature. In addition, an ambient temperature sensor82may be positioned outside cabinet12for measuring a temperature of the environment in which delivery device10is located.

As used herein, “temperature sensor” or the equivalent is intended to refer to any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, temperature sensors80,82may each be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, etc. In addition, temperature sensors80,82may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and/or indicative of the temperature within storage container14or the ambient environment, respectively. Although exemplary positioning of temperature sensors is described herein, it should be appreciated that delivery appliance10may include any other suitable number, type, and position of temperature, humidity, and/or other sensors according to alternative embodiments.

Referring again toFIG. 1, delivery appliance10may include a control panel90including one or more selector inputs92, such as knobs, buttons, touchscreen interfaces, etc. Additionally, a display94, such as an indicator light or a screen, may be provided on control panel90. Control panel90, selector inputs92, and display94may be in communication with a processing device or controller96. In this manner, controller96may receive control inputs from selector inputs92, may display information using display94, and may otherwise regulate operation of the appliance. For example, signals generated in controller96may operate delivery appliance10, including climate control system50and other system components, in response to the position of selector inputs92and other control commands.

FIG. 6depicts certain components of controller96according to example embodiments of the present disclosure. Controller96can include one or more computing device(s)96A which may be used to implement methods as described herein. Computing device(s)96A can include one or more processor(s)96B and one or more memory device(s)96C. The one or more processor(s)96B can include any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field-programmable gate array (FPGA), logic device, one or more central processing units (CPUs), graphics processing units (GPUs) (e.g., dedicated to efficiently rendering images), processing units performing other specialized calculations, etc. The memory device(s)96C can include one or more non-transitory computer-readable storage medium(s), such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, etc., and/or combinations thereof.

The memory device(s)96C can include one or more computer-readable media and can store information accessible by the one or more processor(s)96B, including instructions96D that can be executed by the one or more processor(s)96B. For instance, the memory device(s)96C can store instructions96D for running one or more software applications, displaying a user interface, receiving user input, processing user input, etc. In some implementations, the instructions96D can be executed by the one or more processor(s)96B to cause the one or more processor(s)96B to perform operations, e.g., such as one or more portions of methods described herein. The instructions96D can be software written in any suitable programming language or can be implemented in hardware. Additionally, and/or alternatively, the instructions96D can be executed in logically and/or virtually separate threads on processor(s)96B.

The one or more memory device(s)96C can also store data96E that can be retrieved, manipulated, created, or stored by the one or more processor(s)96B. The data96E can include, for instance, data to facilitate performance of methods described herein. The data96E can be stored in one or more database(s). The one or more database(s) can be connected to controller96by a high bandwidth LAN or WAN, or can also be connected to controller through network(s) (such as network102described below). The one or more database(s) can be split up so that they are located in multiple locales. In some implementations, the data96E can be received from another device.

The computing device(s)96A can also include a communication module or interface96F used to communicate with one or more other component(s) of controller96or delivery appliance10over the network(s). The communication interface96F can include any suitable components for interfacing with one or more network(s), including for example, transmitters, receivers, ports, controllers, antennas, or other suitable components.

As illustrated and described inFIG. 6, controller96includes a memory and microprocessor, such as a general or special purpose microprocessor operable to execute programming instructions or micro-control code associated with methods described herein. However, it should be appreciated that according to alternative embodiments, controller96may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software. Selector inputs92, display94, sensors, and other components of delivery appliance10may be in communication with controller96via one or more signal lines or shared communication busses.

Referring again toFIG. 1, a schematic diagram of an external communication system100will be described according to an exemplary embodiment of the present subject matter. In general, external communication system100is configured for permitting a consumer, a grocery delivery service, or another entity to communicate with and/or control delivery appliance10, e.g., through controller96. For example, this communication may be used to provide and receive delivery notifications or instructions, as described below. Alternatively, such notifications and information may be input directly through control panel90.

As illustrated, external communication system100permits controller96of delivery appliance10to communicate with external devices either directly or through a network102. For example, a consumer may use a consumer device104to communicate directly with delivery appliance10. For example, consumer devices104may be in direct or indirect communication with delivery appliance10, e.g., directly through a local area network (LAN), Wi-Fi, Bluetooth, Zigbee, etc. or indirectly through network102. In general, consumer device104may be any suitable device for providing and/or receiving communications or commands from a user. In this regard, consumer device104may include, for example, a personal phone, a tablet, a laptop computer, or another mobile device.

In addition, a remote server106may be in communication with delivery appliance10and/or consumer device104through network102. In this regard, for example, remote server106may facilitate or operate a grocery delivery service. In this regard, remote server106may be a cloud-based server106, and is thus located at a distant location, such as in a separate state, country, etc. In general, communication between the remote server106and the client devices may be carried via a network interface using any type of wireless connection, using a variety of communication protocols (e.g. TCP/IP, HTTP, SMTP, FTP), encodings or formats (e.g. HTML, XML), and/or protection schemes (e.g. VPN, secure HTTP, SSL).

In general, network102can be any type of communication network. For example, network102can include one or more of a wireless network, a wired network, a personal area network, a local area network, a wide area network, the internet, a cellular network, etc. According to an exemplary embodiment, consumer device104may communicate with a remote server106over network102, such as the internet, to place food orders, process payments, etc. In addition, consumer device104and remote server106may communicate with delivery appliance10to coordinate the delivery and receipt of food items20, as described in detail below.

External communication system100is described herein according to an exemplary embodiment of the present subject matter. However, it should be appreciated that the exemplary functions and configurations of external communication system100provided herein are used only as examples to facilitate description of aspects of the present subject matter. System configurations may vary, other communication devices may be used to communicate directly or indirectly with one or more delivery appliances, other communication protocols and steps may be implemented, etc. These variations and modifications are contemplated as within the scope of the present subject matter.

Now that the construction and configuration of delivery appliance10and external communication system100have been presented according to an exemplary embodiment of the present subject matter, an exemplary method200for operating a delivery appliance using an external communication system is provided. Method200can be used to operate delivery appliance10using external communication system100, or to operate any other suitable delivery appliance using any other suitable communication system. In this regard, for example, controller96may be configured for implementing method200. However, it should be appreciated that the exemplary method200is discussed herein only to describe exemplary aspects of the present subject matter, and is not intended to be limiting.

As shown inFIG. 7, method200includes, at step210, maintaining a storage container of a temperature controlled delivery box at a preconditioning temperature. For example, continuing the example from above, controller96of delivery box10may operate climate control system50to regulate a container temperature (e.g., as measured by container temperature sensor80) to the preconditioning temperature.

As used herein, “preconditioning temperature” is intended to refer to a desired temperature within storage container14which is somewhere between the ambient temperature (e.g., as measured by ambient temperature sensor82) and a target temperature (e.g., the temperature necessary for storage of food items20). Notably, a user, manufacturer, or delivery service may set the preconditioning temperature as needed to ensure storage container14reaches the target temperature prior to or at delivery of food items20.

Method200further includes, at step220receiving a delivery notification. For example, continuing the example from above, delivery appliance10may receive delivery notification of specific food items20from a grocery delivery service through remote network102. Step230includes obtaining a target temperature, which may correspond to the desired temperature or temperatures of storage containers14in order to properly store the specific food items20that are being delivered. Notably, the delivery notification may further include an approximated delivery time delay (e.g. the time delay between receipt of the delivery notification and the delivery of food items20), a target temperature for those food items20, and any other suitable information. Alternatively, the target temperature may be preset by the manufacturer or user of delivery appliance10.

Step240includes operating the climate control system to regulate the container temperature to the target temperature. In this regard, for example, the container temperature may be measured using container temperature sensor80and may be fed back continuously to controller96. Controller96may then operate climate control system50to regulate the container temperature. More specifically, according to an exemplary embodiment, sealed system60may generally be used for lowering the temperature of storage containers14and heating device52may be generally used for raising the temperature of storage containers14. In addition, step250may include returning the storage container to the preconditioning temperature after delivered food items20are removed from the storage container, e.g., to conserve energy. An exemplary temperature profile achieved within storage container14when using method200is provided for example inFIG. 8.

In general, the preconditioning temperature is selected to achieve a balance between reduced energy consumption and ensuring the target temperature may be achieved when a food delivery is expected. For example, according to an exemplary embodiment, the preconditioning temperature is a temperature about half way between an ambient temperature and the target temperature. In this regard, if the ambient temperature is 77° F. and the target temperature is a common refrigerator temperature (e.g., 37° F.), the preconditioning temperature may split the difference at 57° F. In this manner, energy usage is reduced by not maintaining storage container14at 37° F. constantly, while it is still possible for storage container14to reach the target temperature before a delivery of food items20arrives.

According to another embodiment, the preconditioning temperature may be determined or calculated as a function of a regulation capacity of the climate control system, the target temperature, and an estimated delivery delay time. The regulation capacity of the climate control system, for example, is the rate at which climate control system50may lower or raise the temperature within the storage container14(e.g., in degrees per minute). In addition, the estimated delivery delay time may be an approximate time that elapses between when the delivery notification is received and when food items20are delivered.

For example, the delivery delay time may be provided by the grocer when the delivery notification is transmitted, may be an estimated time based on historical delivery data, or may be determined in any other suitable manner. Thus, for example, if the target temperature is 37° F., the climate control system has a regulation capacity of 1° per minute, and the delivery delay time is approximately 30 minutes, the preconditioning temperature can be calculated as 67° F. By contrast, under the same scenario, if the regulation capacity of the climate control system were 0.5° per minute, the preconditioning temperature would be 52° F.

FIG. 7depicts an exemplary control method having steps performed in a particular order for purposes of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that the steps of any of the methods discussed herein can be adapted, rearranged, expanded, omitted, or modified in various ways without deviating from the scope of the present disclosure. Moreover, although aspects of the methods are explained using delivery appliance10and external communication system100as an example, it should be appreciated that these methods may be applied to the operation of any suitable appliance and payment management system.