Abstract:
There is provided a product merchandising display device for cooling products therein and associated methods. The product merchandising display device may include a housing having a tub portion, and a source of water to supply an integrated ice making system. The ice making system dispenses ice into the tub portion, and melted water is removed from the tub portion and recycled to the production of ice by the ice making system. The system provides an interactive experience to the consumer to enhance its attractiveness and impulse sales therefrom. The invention provides an attractive, inviting display in which the articles for sale are made conveniently accessible while providing a display of light and movement of ice to attract the consumer.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/561,985, filed on Nov. 21, 2011, and is incorporated herein by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    This invention relates generally to product merchandising units for use in storing and displaying a wide variety of products to consumers and, more particularly, to a merchandising unit that includes a ice making system and cooler receptacle forming a point of sale product merchandising unit for holding and merchandising chilled products therefrom. 
       BACKGROUND OF THE INVENTION 
       [0003]    In the sale and merchandising of various products, such as single unit products like bottled or canned drinks, fruit juice type beverages, some food items and the like, it is desired to pre-chill such products for immediate consumption. Many convenience or other stores have large refrigerated cases that may allow for this. These wall-mounted, refrigerated product displays are used, but have various deficiencies from the standpoint of promoting effective impulse buying. Either only the front panel or door of such display devices is clear, and the products are displayed in a package form or, if in a single unit, in a disadvantageous marketing position. In addition, wall-mounted units typically are very large and/or permanently mounted in a particular aisle, and thus not portable to various locations around the store or to other locations. A wide variety of products such as soft drinks, fruit juices, beer, wine, prepared sandwiches and the like, might sell much more quickly if the display system could be placed at a location near the checkout counter of the store or other areas of high customer traffic. Impulse buying is effective only when the product is located within the customer&#39;s view, and very large or permanently mounted wall units often are located in areas of low customer traffic. 
         [0004]    To facilitate impulse purchasing of such items, there is a need to have a product merchandising unit which will accommodate the storing and chilling of a reasonable number of such articles for easy access by prospective customers. This is particularly true in the mobile society in which we live, where pre-chilled beverage and other products are many times purchased for consumption on the go. As a result, point-of-sale merchandising units are widely used due to the greater flexibility provided with respect to where such merchandising units may be located. The strategic location of such units can have a significant impact on the sales of the articles or products. The ability to provide merchandising units immediately adjacent areas such as food counters, points of purchase, and other high customer traffic locations, provide better utilization of merchandising areas, and is important to the merchant. 
         [0005]    There is thus a need for other point-of-sale merchandising systems, and merchandising units have thus been developed which are formed as open coolers, using non-renewable amounts of ice cubes in a tub or container, in which the products are placed to pre-cool them. Though somewhat effective, such units have deficiencies in that they must be manually refilled with ice from an outside source as the ice turns to water. If not properly filled with ice, the units may not cool the temperature of the products that need to be cooled uniformly, resulting in a product being sold at an undesired temperature. Further, it is desirable for such units to have a sufficient volume to hold enough product and ice to satisfy periods of high consumer demand, such as on weekends, holidays, and other high consumer traffic periods. At the same time, as the ice in the unit begins to melt, it either creates a body of water in which the products are disposed, or if the water is drained, does not allow for desired display and access to the products that sink into the tub. With such units, it is also possible that the ice and water become contaminated from customers having to put their hand into the ice/water to retrieve an item. It would be desirable to provide a system for automatically sanitizing the ice/water used in the merchandising unit. It may also desirable for the unit to be able to hold a smaller quantity of such products and ice for lower volume periods. This would save costs associated with the ice used in such units. It would be desirable to allow for an effective system to overcome these problems. For these and other reasons, the present invention is directed to overcoming the problems set forth above. 
       SUMMARY OF INVENTION 
       [0006]    The invention overcomes the shortcomings and limitations of the prior art units discussed above and teaches the construction and operation of embodiments of a product merchandising display device adaptable for use in merchandising chilled products. 
         [0007]    The invention also provides an interactive experience to the consumer to enhance its attractiveness and impulse sales therefrom. The invention provides an attractive, inviting display in which the articles for sale are made conveniently accessible while providing a display of light and movement of ice to attract the consumer. 
         [0008]    Further, the invention provides for a system and method for substantially uniform cooling of products in a product merchandising display, which is maintained without intervention by the merchandiser. 
         [0009]    These and other aspects of the invention are embodied within a product merchandising display device for cooling products therein, comprising a housing having a tub portion, and a source of water to supply an integrated ice making system. The ice making system dispenses ice into the tub portion, and melted water is removed from the tub portion and recycled to the production of ice by the ice making system. 
         [0010]    The invention also relates to a system and methods for automatically refreshing ice in a merchandising display device for cooling products therein comprising a stand-alone housing having a tub portion, and a source of water to supply an integrated ice making system. The ice making system dispenses ice into the tub portion on an automated basis, and melted water is removed from the tub portion. If desired, the melted water may be recycled to the production of ice by the ice making system. 
         [0011]    The invention also relates to a system and methods for displaying and merchandising cooled products that includes at least one visible feature including movement of ice or water around the products during the display thereof. 
         [0012]    The invention also relates to a system and methods for sanitizing the ice/water used in the merchandising unit, by filtration or other decontamination of the melted water used in the production of ice for the system. 
         [0013]    The system may include further features, such as a movable base system to allow different amounts of product to be accommodated in the tub portion of the system, water recycling systems, sensor and control systems to monitor and control ice, water levels and/or other systems or functions, advertising systems and lighting and/or audio systems for attraction of customers and other features. 
     
    
     
       DESCRIPTION OF THE FIGURES 
         [0014]    The structure, operation and advantages of a presently preferred embodiment of this invention will become further apparent upon consideration of the following Description, taken in conjunction with the accompanying FIGS. and examples, wherein: 
           [0015]      FIG. 1  is a front elevational view of a display apparatus according to an example of the invention; 
           [0016]      FIG. 2  is a partial cross section of the example of the display apparatus shown in  FIG. 1 ; 
           [0017]      FIG. 3  is a partial exploded view of the display apparatus of the example of  FIG. 1 ; 
           [0018]      FIG. 4  is a partial exploded view of the display apparatus of the example of  FIG. 1 ; 
           [0019]      FIG. 5  is a back perspective view of the ice distribution system according to an example of the invention; 
           [0020]      FIG. 6  is a top view of the ice distribution system according to an example of the invention; 
           [0021]      FIG. 7  is a flow chart showing operational aspects of an example of the invention; and 
           [0022]      FIG. 8  is a schematic illustration of a control system in conjunction with the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]    Referring now to  FIGS. 1-4 , one example of a point-of-purchase, product merchandising apparatus  10  of the invention is illustrated. The product merchandising apparatus  10  includes a base  12  and an upper housing  14  mounted atop the base  12 . The base  12  and upper housing  14  may be formed of any suitable material, such as plastic, metal or similar material. The upper housing  14  may also have various surfaces  15  which allow for high quality graphics to be displayed, forming a unit that becomes a beautiful and inspirational display in conjunction with other features as will be discussed below. This enhances the ability to attract consumers to try one of the products pre-chilled therein. The panels  15  may be vacuum formed plastic, and the unit may allow for interchangeable graphics to be displayed on the surfaces  15 . Backlighting may be provided for enhancing the visibility of the graphics or for producing lighting effects. LED lighting may be used for energy saving and simplicity for example. The base  12  may be constructed to provide stability, and may be supported on the floor by lockable rollers  19 , pads or the like, to facilitate transport thereof. In general, the product merchandising apparatus  10  is portable and can be readily moved to different locations at a particular retail establishment, or to different retail or other venue. For example, the apparatus may be used in convenience stores, hotels, convention centers, stadiums, other kiosk applications, events where self-service is desired such as weddings, receptions, casual dining and the like. 
         [0024]    The base  12  further includes a tub portion  16  defining an open interior for displaying beverage, food or other items. The tub portion  16  may be formed as a singular space or may be divided into compartments or the like if desired. The interior portion provides the chilling space into which ice and products are disposed for pre-chilling the products for purchase by a consumer. The tub portion  16  has insulation disposed around it to maintain a chilling temperature within the tub portion  12 . The tub portion  16  may be formed integral to the base  12  or may be provided as a separate unit that is mounted on the base  12 . Though the base  12  and tub portion  16  are shown with a flat back surface, to be disposed adjacent a counter, wall, another system  10  or the like, it could also be formed such that the tub portion extends around the entire housing to be accessible from any direction. The tub portion  16  could also be supported on a lazy-susan type bearing to allow the tub portion  16  to be rotated so as to be visually appealing. Like the upper housing  14 , the base  12  may also have various surfaces  18  which allow for high quality graphics to be displayed. The larger surfaces  18  of the base  12  allow for a wide variety of graphics/advertising to be displayed, to enhance attracting consumers to try one of the products pre-chilled therein. The panels  18  may be vacuum formed plastic, and the unit may allow for interchangeable graphics to be displayed on the surfaces  18 . Backlighting may be provided for enhancing the visibility of the graphics or for producing lighting effects, such as by LED lighting. There may also be provided an audio generating system in the upper housing  14  and/or base  12 , to play sound/music or other audio. Other devices to enhance the visual or other appeal of the system  10  may be used, such as video displays for example. Further, it may be desirable to form the tub portion  16  to have a variable volume to assist in storing different quantities of products therein. To allow for this, the position of the bottom surface of the tub portion may be made to be adjustable, either manually or automatically, to adjust the volume of the tub portion. In this way, for times of lower volume activity, the volume of the tub portion  16  may be reduced to hold less product, but to display it in a visually appealing manner. In some cases, if a lower volume of products is placed in a tub portion of a greater volume, the appearance of the display of products may not be as desired, and vice versa, so it may be desirable to provide the system  10  with such volume adjustment capability. It is also possible to provide additional attributes in association with the tub portion  16 , such as individual holders for beverages or other products disposed around the tub portion  16  to allow display of such items in a desired manner. It may also be possible to provide an automatic product dispensing system which could be used to automatically refill the tub portion with a desired amount of product after chilled product has been taken therefrom. It may also be desirable to provide a product distribution system to allow products to be refilled in a somewhat uniform manner around the tub portion  16 . 
         [0025]    The upper housing  14  includes an integrated ice making system  20  as seen in  FIGS. 2 and 4 , which is mounted over the tub portion  16  to automatically and controllably dispense ice into the tub portion  16 . One or multiple units  20  may be used as may be desired. The ice maker may  20  be of any suitable design, but as an example, may be designed to instantly make clear ice when actuated. The ice maker  20  may be a crystalline ice bullet head, and may be selectively controlled to make different ice cube sizes. The maker  20  may include an ice management system, and be designed to allow for production of a predetermined amount of ice in response to the environment in which the unit  10  is used. A temperature sensor may monitor the temperature of the local environment and if the ambient temperature is hot, then the freeze cycle time of ice maker  20  may be lengthened to produce consistent ice cube size. If the ambient temperature is cool, then the freeze cycle time of ice maker  20  may be shortened to produce consistent ice cube size. A temperature sensor may also be used to monitor the temperature in the tub portion  16 . When ice has been produced to create a predetermined temperature in the tub portion  16 , ice production is stopped until ice in the tub portion  16  has melted to a degree and then the ice maker  20  is turned back on. The ice maker  20  may be controlled to produce consistent ice cube sizes and keep the tub portion  16  full of ice as desired. The ice maker  20  could also be controlled to produce a predetermined ice per time period, such as 12 ice cubes per 10 minutes, or other suitable amount. The ice maker  20  may have a predetermined ice capacity, such as between 25 to 40 pounds per 24 hours. The maker  20  may include a water level control or management system to ensure proper operation, and may use a control system to automatically control operation. For example, the control system may allow for programmable operation, to allow features such as automatic On/Off features based on opening hours of a retail store, automatic water level control or management and shut-off features based on low water levels, power saving features, temperature sensor control based on local environment, and other desired functions or characteristics. The control system may also be configured to allow two units  10  to be disposed back-to-back for example, with the control systems of the multiple units working together in a coordinated manner, such as by forming a master/slave configuration between the units. 
         [0026]    Turning to  FIG. 8 . in an example, a control system  150  may include a central processing unit (CPU), programmable logic controller (PLC) or other suitable system, that is suitably programmed to implement desired operation of the units  10 . As shown in this example, alternative example of the unit  10  includes a visual or light indicator  160 , such as one of more LED&#39;s, and sound alert indicator  162 , associated with a control panel  164  on the back of unit  10 . Another light indicator  166 , such as one of more LED&#39;s, may be provided on a front indicator panel  168 . The light indicators  160  and  166  in the front and back allow clear communication of the operation of unit  10  for ensuring proper operation. Further, the sound alert indicator  162  in conjunction with the light indicators enables alerting personnel to any problem or need for attention to continue desired operation of unit  10 . The control system  150  may thus include a light and sound indicator control  152  connected to the light indicators  160  and  166 , and to sound alert indicator  162 . The CPU is set via a control  154  to either preset parameters for operation of the unit  10 , or User settings, that may be input by the user to accommodate particular environmental or other conditions or requirements. Further, a water sensor control and/or motor control  156  may be provided in association with a suitable sensor connected with the ice machine  20  and/or suitable motor controller to operate ice dispensing characteristics. If the ice machine  20  is not being supplied with sufficient water, an alert may be provided by the light and/or sound indicators  160 ,  162  and/or  166 . Suitable maintenance or repair can then be initiated. Similarly, a height of ice and/or temperature control  158  may be provided in association with a suitable ice height and/or temperature sensor connected with the ice bin or tub portion  16 . If the ice in tub portion  16  is not at a desired height and/or providing the desired temperature within the tub portion, an alert may be provided by the light and/or sound indicators  160 ,  162  and/or  166 . Suitable maintenance or repair can then be initiated. Also, a water level sensor control  159  may be provided in association with a suitable water level sensor connected with the water tank or reservoir  30  of unit  10 . If the water reservoir  30  does not have enough or is not being supplied with sufficient water, an alert may be provided by the light and/or sound indicators  160 ,  162  and/or  166 . Suitable maintenance or repair can then be initiated. In operation, the control system  150  may control operation of the ice maker  20  using a water sensor to detect inside water level, the temperature sensor to control the timing of making ice, and/or to control operation of the motor to control the motion or dispensing characteristics of the ice maker when it drops ice. Other sensors or controllers may be used if desired, such as in association with a water pump  32  or associated filter or the like as described below, one or more fans to cool motors/pumps or other components of unit  10 , or the like. 
         [0027]    There is also provided an ice distribution system  22  mounted below the ice making system  20  that facilitates uniform distribution of ice into the tub portion  16 . In this example, the ice distribution system  22  is shown in  FIGS. 5 and 6 , is a member that slopes outwardly from a top portion thereof. In position, the top is adjacent the location of dispensing ice from the ice making system  20  and system  22  is tapered outwardly to a position above the tub portion  16 . As the ice making system  20  is disposed above the tub portion  16 , ice dispensed therefrom is directed by gravity to the open tub portion  16 . As an example, the ice distribution system  22  may be formed into a simulated shape, such as a mountainside type shape or some other natural or manufactured shape or object. The ice distribution system  22  may also include several channels  24  or other guides to allow ice dispensed from the ice making system  20  in a substantially uniform manner into the tub portion  16 . The ice making system  20  may also have an ice distribution controller, such as a motor and associated ice handling system, to allow ice once it is made to be distributed at a desired location relative to the ice distribution system  22 . The ice distribution controller could be one or more chute type of members that can be stationary or movable by a motor controller for example. In addition, the ice distribution system  22  provides a visually appealing feature in association with the unit  10 , as ice dispensed from the ice making system is directed to slide down the extending surface of the ice distribution system  22 . The ice distribution system  22  may be vacuum formed plastic for example, and backlighting may be provided for producing dramatic lighting effects. Other visually appealing characteristics could be utilized, such as dispensing water, mist or the like, along with ice. 
         [0028]    As seen in  FIG. 4 , the system includes functions to support the production of ice and other attributes of the system, comprising a water reservoir  30  for containing an amount of water to support ice production. A water pump  32  is provided and pumps water from reservoir  30  to a filtration system  34 . The water filtration system may be of any suitable type, but preferably includes a solids removal system in addition to filtering to remove any solid materials that may end up in the system. The filtration system may also include a system to remove pathogens such as reverse osmosis and/or ultraviolet (UV-C) systems. As will be described below, after ice production, the ice in the tub portion  16  will melt, and such melted water is drained from tub portion  16  back to the water reservoir  30  via a drain tube  36 . In this manner, the system continually decontaminates the water used in the system and allows for the production of clean ice. The water reservoir  30  may include one or more water level sensors associated therewith, to indicate a low, sufficient and/or high water level in the system  10 . If a low water level is detected, the system may include some type of alarm or indicator, such as a light and/or sound indicator  160 ,  162  and/or  166  described above, to inform staff that the water reservoir needs filled. But, as water is recycled in the system  10 , the need for refilling is minimized. Alternatively, if a source of water is available at the site of the system  10 , the use of a water reservoir may be optional, and the water source could be directly connected to the ice making system. If a separate water source is used, drained water may still be recycled or may be discarded. 
         [0029]    Turning now to  FIG. 7 , the ice cube manufacturing and operation process cycle is shown. First at  100  the water is filled into a tank located at the rear of the cooler from an outside source. At  102  the water is then pumped from the water tank through a water filtration system at  104 . The filtered water is then pumped to the ice cube maker contained in the housing above the cooler tray. The ice maker is then operated to implement an ice production cycle at  106 , and to dispense the newly formed ice cube out of the ice cube maker and dropped to the cooler tub via a the ice distribution system such as via the multi-way channels. The ice cubes then distribute themselves evenly around the product in the cooler tub to reduce the temperature of the product. As the ambient temperature is higher than that of the ice cubes the ice cubes turn into water and drain down to the water tank at  108  via at least one drainage hole located in the base of the cooler tub and is recycled to the ice maker for further ice production. As the recycled water decreases by evaporation the operator must refill the water tank. 
         [0030]    It should be evident from the foregoing that the system  10  provides many attributes, including that the system requires less maintenance to operate at optimum operating levels because the melted ice cubes can be replaced with new ones automatically. Further, the filtration system ensures any solid material is removed ensuring the ice cubes appear more uniform. Due to the effect of gravity on the ice cubes as they are released from the top of cooler and guided down to the cooler tub, the ice distribution system  22  ensures equal distribution of ice ensuring the whole tub is being cooled, not just in one section. This effect also captures the consumers&#39; attention and resembles that of a mountain avalanche or water bead on a bottle. 
         [0031]    Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the instant invention will include all embodiments falling within the scope of the appended claims.