Abstract:
A method of transporting and assembling components of a merchandise display system having one or more display units. The components of the merchandise display system may be shipped to and received at a merchandising location and may lay flat and stack on top of each other during transportation. The components of the merchandise display system may be assembled at the merchandising location. One or more of the components may be pre-assembled and shipped to and received at the merchandising location to be assembled with the remaining components of the merchandising display system. The merchandise display system may include a base unit having a refrigeration unit that cools one or more display units. The refrigeration unit may be removable from the base unit. The display units may be stackable on top of one another and be configured to attach to the base unit.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part application of U.S. application Ser. No. 13/173,351, filed Jun. 30, 2011. This application is incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention relates generally to a modular refrigerated display system for storing and dispensing merchandise. 
       BACKGROUND 
       [0003]    Commercial refrigerators have had the same design and construction for many years. Commercial refrigerators are typically large heavy boxes that have failed to keep up with design trends and consumer expectations. Because of the large size, commercial refrigerators are often under-utilized and only partially filled. The walls of commercial refrigerators are generally formed from two thin steel plates with insulating polyurethane foam injected between them. This construction makes the commercial refrigerators heavy, time-consuming to build, and difficult to recycle. Additionally, many of the commercial refrigerators have negative impacts to the environment because of the type of refrigerant and compressor used. 
       SUMMARY OF THE INVENTION 
       [0004]    An object of this invention described herein is to provide a light weight modular refrigerated merchandise display system that may be customized depending on the amount of space required. Another object of the invention is to provide visual access of the merchandise within the display system to a customer from one or more angles. Another object of the invention is to provide an easily accessible and replaceable refrigeration unit. 
         [0005]    In one aspect of the invention, a merchandise display system includes one or more display units. The one or more display units may include at least one shelf and at least one door for accessing the display unit. The merchandise display system may include a base unit. The base unit may be removable from the merchandise display system. The base unit may also include a cooling system configured to cool the one or more display units and a sensor system configured to sense environmental parameters within the one or more display units. The one or more display units may be attached to the top of the base unit. In at least one embodiment, the merchandise display system includes a plurality of display units attached one on top of each other with the lowermost display unit attached to the top of a base unit. 
         [0006]    In another aspect of the invention, a merchandise display system includes one or more display units. In at least one embodiment of the invention, the merchandise display system includes a plurality of display units positioned back to back. In this embodiment, each of the display units includes a plurality of top doors and a plurality of bottom doors. Each display unit may further include a plurality of shelves. The plurality of shelves may be movable within the merchandise display system. Each of the display units may also include a refrigeration unit, which may be removable from the display unit. 
         [0007]    In another aspect of the invention, components of a merchandise display system are shipped flat to a merchandising location and assembled at the merchandising location. In at least one embodiment of the invention, one or more components of a merchandise display system, such as doors, side walls, top walls, bottom walls, front walls, shelves, and back walls are stacked on top of each other and adjacent each other and are shipped to a merchandising location in a generally flat configuration. In this embodiment, the components are assembled at a merchandising location to form a modular refrigerated merchandise display system that includes a base unit and one or more display units. The base unit may include a cooling system that is removable from the base unit. In an alternative embodiment, the base unit is pre-assembled and shipped to the merchandising location separately from the components for the one or more display units. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective view of a merchandise display system in accordance with at least one embodiment of the present invention; 
           [0009]      FIG. 2   a  is a perspective view of a base unit and a display unit in accordance with at least one embodiment of the present invention; 
           [0010]      FIG. 2   b  is a perspective view of a base unit; 
           [0011]      FIG. 3  is an alternative embodiment of the merchandise display system of  FIG. 1 ; 
           [0012]      FIG. 4  is a perspective view of an alternative embodiment of the merchandise display system in accordance with the present invention; 
           [0013]      FIG. 5  is a perspective front view of the merchandise display system of  FIG. 4 ; 
           [0014]      FIG. 6   a  is an exploded perspective view of the shelving system in accordance with at least one embodiment of the present invention; 
           [0015]      FIG. 6   b  is a perspective view of the shelving system of  FIG. 6   a ; and 
           [0016]      FIG. 7  is a perspective partial side view of the merchandise display system of  FIG. 4 . 
           [0017]      FIG. 8   a  is an exploded perspective view of the components of a display unit in accordance with at least one embodiment of the present invention. 
           [0018]      FIG. 8   b  is an exploded perspective view of the components of a base unit in accordance with at least one embodiment of the present invention. 
           [0019]      FIG. 9  is a perspective view of the components illustrated in  FIGS. 8   a  and  8   b  configured to be shipped in accordance with at least one embodiment of the present invention. 
           [0020]      FIG. 10  illustrates an example method for shipping and assembling the components of a merchandise display system in accordance with at least one embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    Referring to  FIGS. 1 and 3 , the merchandise display system according to one embodiment of the present invention is indicated generally at  10 . The merchandise display system  10  may be of a modular construction and include a plurality of display units  100  and a base unit  200 . The display units  100  and base unit  200  may be made of any suitable material, such as plastic or metal. In one embodiment, the display units  100  are hollow structures filled with a foam-based insulation material, which may reduce the weight of the merchandise display system  10 . In one embodiment, the base unit  200  is also a hollow structure filled with a foam-based insulation material, which may reduce the weight of the merchandise display system  10 . 
         [0022]    The display units  100  and base unit  200  may be any suitable size or shape. In one example, as illustrated in  FIG. 1 , the display units  100  and base unit  200  are generally cube shaped. Alternatively, as illustrated in  FIG. 3 , the display units  100  and base unit  200  may be generally trapezoidal. Any suitable shape is contemplated within the scope of this invention, such as a rectangle, circular, or oval shape. The display units  100  and base unit may be the same shape or different shapes. 
         [0023]    Referring back to  FIG. 1 , each of the plurality of display units  100  includes a top wall  120 , two side walls  140 , a bottom wall  130 , a door  150 , and a back wall  160 . The door  150  may be made of any suitable material, such as glass or plastic. In at least one embodiment, the door  150  is transparent to allow visual access to the product stored and displayed within the display unit  100 . The door  150  may open in any suitable manner. For example, in at least one embodiment, one side of the door  150  is hingedly attached to the display unit  100  and the door  150  swings open to allow access to the display unit  100 . In at least one embodiment, the door  150  includes a handle for opening the door  150 . 
         [0024]    Each of the display units  100  may include one or more shelves  170 . The shelves  170  may be movable within the display units  100  to accommodate different types or heights of products. Any number of shelves  170  is contemplated within the scope of this invention. The number of shelves  170  may be dependent on the size of the merchandise displayed in the display unit  100 , may be dependent on the size of the display unit  100 , or a combination of both. 
         [0025]    Each display unit  100  may have a lighting system controlled by an electrical module in the base unit  200 . In at least one embodiment, the lighting system includes eight light emitting diodes (“LEDs”)  180  installed on the inner surface of each of side walls  140  of the display units  100 , as illustrated in  FIG. 1 . The lighting system may also include exterior lights to attract customers to the merchandise display system  10 . 
         [0026]    Referring to  FIGS. 2   a  and  2   b , the base unit  200  has a top wall  220 , a bottom wall  230 , two side walls  240 , a back wall  260  and a front wall  250 . In at least one embodiment, the front wall  250  may be a door. The door may open in any suitable manner. For example, the door may be hinged on one side and swing open to allow access into the base unit  200 . In another embodiment, the front wall  250  may be a front portion of a drawer housed within the base unit  200 . In this embodiment, the drawer may slide out of the base unit  200 . The front wall  250  may be a solid construction or may contain apertures to allow air to flow into and out of the base unit  200 . 
         [0027]    The base unit  200  may include a cooling system and sensor system. The sensor system may be configured to sense the environment within the display units  100 . For example, the sensor system may be configured to detect the temperature or humidity in the interior of the display units  100 . In at least one embodiment, the sensor system is in communication with the cooling system in the base unit  200 . 
         [0028]    As illustrated in  FIG. 2   b , the cooling system may include a refrigeration unit  210  that is configured to cool the interior of the plurality of display units  100 . The refrigeration unit  210  may cool any number of display units  100 . For example, the refrigeration unit  210  may cool one display unit  100  or four display units  100 . In at least one embodiment, the refrigeration unit  210  is configured to cool three display units  100 . In at least one embodiment, the refrigeration unit  210  is removable from the base unit  200 . The refrigeration unit  210  may cool each display unit  100  is any suitable way. In one embodiment, a hose is connected from the refrigeration unit  210  to each of the display units  100 . In this embodiment, the hose transports air from the base module and sends it to the display units  100 . 
         [0029]    The refrigeration unit  210  may include typical refrigeration components such as a compressor, a condenser, an evaporator, a fan, etc. The refrigeration unit  210  may use any suitable type of refrigerant to cool the merchandise display system  10 . For example, R134A (tetraflouroethane), CO2 (carbon dioxide), or hydrocarbons may be used. The refrigeration components may be placed within the same enclosure in the refrigeration unit  210  and separated as necessary by insulating material. Alternatively, some of the refrigeration components may be placed in separate enclosures within the refrigeration unit  210 . 
         [0030]    The merchandise display system  10  may utilize any applicable insulation. In one embodiment, the merchandise display system  10  incorporates Aerogel insulation material. Specifically, the merchandise display system may incorporate Spaceloft insulation. The use of Spaceloft insulation may decrease the required thickness of the walls of the display system  10 . Insulation may also be used in the refrigeration unit  210  to separate the condenser and evaporator within the same refrigeration unit  210 . 
         [0031]    In one embodiment, the refrigeration unit  210  may be a hybrid convection-conduction refrigeration system. In this embodiment, the refrigeration unit  210  may include a traditional vapor-compression system, which forces cool air from the refrigeration unit  100  through the display units  100  in the merchandise system  10 . The merchandise displayed in the merchandise display system  10  may be cooled through a conduction process where thermal energy is passed from the shelves  170  to the merchandise to cool the merchandise. In this embodiment, heat generated during the cooling process is transferred out of the refrigeration unit  210  and display units  100 . 
         [0032]    Each display unit  100  may be configured to attach to the base unit  200  or another display unit  100 . In this embodiment, each display unit  100  is configured to engage with or attach to the top wall  220  of a base unit  200 . Each display unit  100  may also be configured to engage with a top wall  120  of another display unit  100 . In at least one embodiment, as depicted in  FIGS. 1 and 3 , the merchandise display system  10  includes a single base unit  200  and three display units  100   a - c . In this embodiment, the base unit  200  is located at the bottom. A first display unit  100   a  is attached to the top wall  220  of the base unit  200 . A second display unit  100   b  is attached to the top wall  120  of the first display unit  100   a  and a third display unit  100   c  is attached to the top wall  120  of the second display unit  100   b . In one embodiment, as illustrated in  FIG. 2   a , the base unit  200  may be of unitary construction with one of the display units  100 . 
         [0033]    The display units  100  may be attached to the base unit  200  and other display units  100  in any suitable manner. In at least one embodiment, the display units  100  and the base unit  200  are attached together through the use of corresponding rails. In this embodiment, the base unit  200  may include one or more rails on the top wall  220  of the base unit  200 , which engages with one or more corresponding rails on the bottom wall  130  of a base unit  100 . The display units  100  may attach to each other in a similar manner. For example, each of the display units  100  may include one or more rails on each of the top walls  120 , which may attach to one or more corresponding rails on the bottom walls  130  of another display unit  100 . In this embodiment, the rails keep the display units  100  and base unit  200  aligned to give the appearance of a single refrigerator. However, display units  100  may be added or removed depending on the amount of space required. 
         [0034]    The merchandise display system  10  may include logos or signs to further promote the brand or type of merchandise within the merchandise display system  10 . The logos and signs may be place on any suitable surface of the merchandise display system  10 . For example, a sign may be placed on the top wall  120  of the top display unit  100  or logos may be attached to the doors  150  or side walls  140  of the display units  100 . 
         [0035]    In another aspect of the invention, as illustrated in  FIG. 4 , a plurality of display units  500  combine together to form a 360 degree merchandise display system  10 . The merchandise display system  10  may include any number of display units  500 . In at least one embodiment, the display system  10  includes two display units  500 , positioned back to back. The display units  500  may be made of any suitable material, such as metal or plastic. In one embodiment, the display units  500  are hollow structures filled with a foam-based insulation material, which may reduce the weight of the merchandise display system  10 . 
         [0036]    The display units  500  may include a top wall  520 , a bottom wall  530 , a back wall  540 , and a front wall  510 . The front wall  510  may include a plurality of upper doors  560  and a plurality of lower doors  550 . The display units  500  may contain any suitable number of upper doors  560  and lower doors  550 . In at least one embodiment, each of the display units includes at least three upper doors  560  and three lower doors  550 . The upper doors  560  and lower doors  550  may be made of any suitable material such as glass or plastic. In at least one embodiment, the upper doors  560  and lower doors  550  are transparent to allow visual access of the merchandise within the display unit  500 . The display units  500  may be any suitable shape and size. For example, the display units may be square, rectangular, circular, semi-circular, or polygonal. 
         [0037]    The upper doors  560  and lower doors  550  may open in any suitable manner. For example, one side of the upper doors  560  may be hingedly attached to the front wall  510  and swing outwardly to allow access to the display unit  500 . In at least one embodiment, the bottom edge of the lower doors  550  is hingedly attached to the display unit  500  to allow the bottom door  550  to open outwardly from the top edge of the door  550 . In at least one embodiment, the upper doors  560  and the lower doors  550  include a handle to aid in opening the upper doors  560  and lower doors  550 . 
         [0038]    The merchandise display system  10  may include a plurality of shelves  570 . The plurality of shelves  570  may be made of any suitable material, such as plastic or metal. In at least one embodiment, the plurality of shelves  570  are wire structures. In at least one embodiment, the plurality of shelves  570  may be tilted or angled. The plurality of shelves  570  may be angled such that the front of the shelves  570  is lower than the back of the shelves  570 . In this embodiment, gravity forces the merchandise displayed on the plurality of shelves  570  forward towards the front of the shelves  570 . Alternatively, the plurality of shelves  570  may be in a horizontal position within the merchandise display system  10 . The plurality of shelves may be any suitable shape. For example, the plurality of shelves  570  may be a triangular or rectangular shape. 
         [0039]    As illustrated in  FIGS. 6   a  and  6   b , the plurality of shelves  570  may further include a basket  575  for the merchandise to be placed in. The basket  575  may rest on top of the plurality of shelves  570  or the shelves  570  may form a frame around the basket  575  and support the basket  575 . In one embodiment, the plurality of shelves  570  are triangular frames that support a triangular plastic basket within the frame. In at least one embodiment, the plurality of shelves  570  are movable to different heights within the display unit  500  to accommodate merchandise of different heights. In at least one embodiment, the baskets  575  and the shelves  570  are removable from the merchandise display system  10 . Any number of shelves  570  are contemplated within the scope of this invention. The number of shelves  570  may depend on many factors, such as the size of the display unit  500  and the size of the product being merchandised. 
         [0040]    As illustrated in  FIG. 7 , the merchandise display system  10  may include a base unit  700 . In one embodiment, the base unit  700  is removable from the merchandise display system  10 . In an alternative embodiment, the base unit  700  is attached to or integral to the merchandise display system  10 . The base unit  700  includes a refrigeration unit  710  and a housing  720 . The housing  720  may be made of any suitable material and may be of solid construction or may include a plurality of apertures to allow air to flow into and out of the base unit  700 . 
         [0041]    In at least one embodiment, the refrigeration unit  710  may be removable from the base unit  700 . The removable refrigeration unit  710  allows for easy installation and maintenance of the refrigeration unit  710 . For example, a technician may chose to replace the removable refrigeration unit  710  rather than repair it while it is connected to the merchandise display system  10 . 
         [0042]    The refrigeration unit  710  may include typical refrigeration components such as a compressor, a condenser, an evaporator, a fan, etc. The refrigeration unit  710  may use any suitable type of refrigerant to cool the merchandise display system  10 . For example, R134A (tetraflouroethane), CO2 (carbon dioxide), or hydrocarbons may be used. The refrigeration components may be placed within the same enclosure in the refrigeration unit  710  and separated as necessary by insulating material. Alternatively, some of the refrigeration components may be placed in separate enclosures within the refrigeration unit  710 . 
         [0043]    The merchandise display system  10  may utilize any applicable insulation. In one embodiment, the merchandise display system  10  incorporates Aerogel insulation material. Specifically, the merchandise display system may incorporate Spaceloft insulation. The use of Spaceloft insulation may decrease the required thickness of the walls of the display system  10 . Insulation may also be used in the refrigeration unit  710  to separate the condenser and evaporator within the same refrigeration unit  710 . 
         [0044]    In one embodiment, the refrigeration unit  710  may be a hybrid convection-conduction refrigeration system. In this embodiment, the refrigeration unit  710  may include a traditional vapor-compression system, which forces cool air from the refrigeration unit  710  through the display units  500  in the merchandise system  10 . The merchandise displayed in the merchandise display system  10  may be cooled through a conduction process where thermal energy is passed from the shelves  570  to the merchandise to cool the merchandise. In this embodiment, heat generated during the cooling process is transferred out of the refrigeration unit  710  and display units  500 . 
         [0045]    The merchandise display system may further include a lighting system. The lighting system may include interior and exterior lighting. In at least one embodiment, the display units  500  include a plurality of exterior lights  580 . The exterior lights  580  may be any suitable type of lighting, such as LEDs. The exterior lights  580  may extend vertically on the front wall  510  of the display unit  500 . The exterior lights  580  may extend from the top wall  520  to the bottom wall  530  or may extend along only a portion of the front wall  510 . 
         [0046]    The display units  500  may further include a sensor system. The sensor system may be configured to sense the environment within the display unit  500 . For example, the sensor system may be configured to detect the temperature or humidity in the interior of the display units  500 . In at least one embodiment, the sensor system is in communication with the cooling system in the base unit  700 . 
         [0047]    The merchandise display system  10  may include logos or signs to further promote the brand or type of merchandise within the merchandise display system  10 . The logos and signs may be place on any suitable surface of the merchandise display system  10 . For example, a sign may be placed on the top wall  520  of the display unit  500  or logos may be attached to the upper doors  560  and lower doors  550 . 
         [0048]    In accordance with at least one of the embodiments described above, all or portions of the merchandise display system  10  may be shipped as component pieces and assembled at a merchandising location, such as a retail store. As illustrated in  FIGS. 8   a  and  8   b , each of the components of a display unit  100  and a base unit  200  may be separate from each other and attached together to form one or more display units  100  or base units  200 . For example, as illustrated in  FIG. 8   a , two side walls  140  may attach to a top wall  120 . A back wall  160  may attach to the two side walls  140  and the top wall  120 . A bottom wall  130  may attach to the two side walls  140  and the back wall  160 . A door  150  may attach to one or more of the bottom wall  130 , two side walls  140 , and the top wall  120  to form a display unit  100 . In at least one embodiment, the display unit  100  includes a plurality of shelves  170  that are attached to at least the two side walls  140  and are configured to display product within the display unit  100 . 
         [0049]    The components of a base unit  200  may be assembled in a similar manner as the components for the display unit  100 . As illustrated in  FIG. 8   b , two side walls  240  may attach to a top wall  220 . A back wall  260  may attach to the two side walls  240  and the top wall  220 . A bottom wall  230  may attach to the two side walls  240  and the back wall  260 . A front wall  250  may attach to one or more of the bottom wall  230 , two side walls  240 , and the top wall  220  to form a base unit  200 . The base unit may further include a cooling system that is removable from the base unit  200 . The cooling system may include a refrigeration unit  210  and a sensor system. 
         [0050]    The components of the display units  100  and the base units  200  may be assembled in any order and may be attached to each other in any suitable manner. For example, the one or more of the components may include tabs that cooperate with corresponding apertures on another component to attach two or more components together. The components may include projections that cooperate with a corresponding aperture on another component to attach two or more components together. Other types of attachment mechanisms, such as cam locks, locking latches, and locking brackets may be used to lock two or more components to each other. 
         [0051]    In at least one embodiment, some or all of the components of a merchandise display system  10  may be shipped flat to the merchandising location. As illustrated in  FIG. 9 , the components of one or more base units  200  and one or more display units  100  may be stacked on top of each other or positioned next to each other and shipped in a generally flat configuration. For example, the side walls  140 , door  150 , top wall  120 , bottom wall  130  and back wall  160  of a display unit  100  may be stacked one on top of each other and positioned in a box next to the side walls  240 , front wall  250 , top wall  220 , bottom wall  230  and back wall  260  of a base unit  200 , which may also be stacked on each other. Any number of components may be shipped flat to the merchandising location. 
         [0052]      FIG. 9  illustrates an example method of assembling a merchandise display system  10  incorporating one or more features described above. In step  1005 , one or more of the components of a merchandise display system  10  are shipped in a generally flat configuration to a merchandising location, such as a retail store, and received at the merchandising location. The components may include one or more of the following: top walls  120 ,  220 ; bottom walls  130 ,  230 ; side walls  140 ,  240 ; back walls  160 ,  260 ; doors  150 , front walls  250 , and a plurality of shelves  170 . A cooling system, including a refrigeration unit  210  and sensor system may be shipped and received with the components or may be pre-assembled and shipped or received separately from the components. In one embodiment, the base unit  200  is pre-assembled and shipped and received separately from the components of the display units  100 . 
         [0053]    In step  1010 , one or more of the components are assembled together at the merchandising location. For example, a top wall  120 , bottom wall  130 , two side walls  140 , a back wall  160  and a door  150  are attached together to form a display unit  100 . The display unit  100  may include one or more shelves  170 . In step  1010 , the components of a base unit  200  may also be assembled together. For example, a top wall  220 , bottom wall  230 , two side walls  240 , a back wall  260 , and a front wall  250  may be attached to form a base unit  200 . The base unit may further include a cooling system that is removable from the base unit  200 . The cooling system may include a refrigeration unit  210  and a sensor system. One or more display unit  100  and base unit  200  may be assembled in step  1010 . 
         [0054]    In step  1015 , a first display unit  100  is attached to a top surface of a base unit  200 . The first display unit  100  may be attached to the base unit  200  in any suitable manner. For example, as discussed above, the first display unit  100  and the base unit  200  are attached together through the use of corresponding rails. The base unit  200  may include one or more rails on the top wall  220  of the base unit  200 , which engage with one or more corresponding rails on the bottom wall  130  of the first base unit  100 . 
         [0055]    In step  1020 , a second display unit  100  may be attached a top surface of the top wall  120  of the first display unit  100 . The display units  100  may attach to each other in a similar manner as the first display unit  100  and base unit  200 . For example, each of the display units  100  may include one or more rails on each of the top walls  120 , which may attach to one or more corresponding rails on the bottom walls  130  of another display unit  100 . The rails may keep the display units  100  and base unit  200  aligned to give the appearance of a single modular refrigerator system. Any number of display units  100  may be attached to each other in step  1020 . 
         [0056]    As discussed above, the merchandise display system  10  may be any size. For example, the merchandise display system  10  may be a suitable size to display on a countertop or may be the size of a commercial refrigerator. The merchandise display system  10  may include one or more doors  150  that cover the front of the display units  100 . The merchandise display system  10  may include one door  150  for each of the display units  100 . Alternatively, one door  150  may extend vertically or horizontally to cover more than one display unit  100 . In at least one embodiment, a single door  150  covers a plurality of display units  100  that are stacked on top of each other. In an alternative embodiment, a single door covers a plurality of display units  100  that are positioned adjacent each other. 
         [0057]    While the invention has been described with respect to certain preferred embodiments, as will be appreciated by those skilled in the art, it is to be understood that the invention is capable of numerous changes, modifications and rearrangements and such changes, modifications and rearrangements are intended to be covered by the following claims. Additionally, one of ordinary skill in the art will appreciate that the steps illustrated in the illustrative figures may be performed in other than the recited order, and that one or more steps illustrated may be optional in accordance with aspects of the disclosure.