Abstract:
A refrigerated cooler for storing food and other applications having a controller and a temperature sensor that monitors the temperature inside the food compartment and compares the monitored temperature to a stored predetermined temperature and a controller controlled door lock that is placed in the lock position by the controller if the monitored temperature is compared to be greater than the stored predetermined temperature or if the supply of power to the cooler is interrupted to restrict a customer&#39;s access to the food inside that may be unsafe due to the monitored temperature being greater than the stored predetermined temperature.

Description:
RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional App. No. 61/833,493 filed Jun. 11, 2013 which is incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates generally to refrigerated coolers and more specifically to refrigerated coolers that prevent access to contents of the cooler when the temperature of the cooler has risen above a safe value. 
       BACKGROUND ART 
       [0003]    Coolers that have a refrigeration system and maintain the food inside at a pre-recorded limits are known in the industry. Industry standards require that certain foods be refrigerated. Still further, some foods are unsafe for human consumption when their temperature during storage rises above a certain temperature. There has also been in increase in the number of unattended and lightly staffed micro-sites where human monitoring of food storage temperature may be insufficient. 
         [0004]    There is a need in the industry for a cooler that automatically prevents access to the food items when their temperatures have risen above a certain temperature. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention provides a cooler equipped with a temperature sensor for monitoring the temperature inside the cooler. When the temperature drops below a minimum level for more than a predetermined length of time, the cooler controller locks the door and prevents access to the food stored inside. The situation usually occurs when the cooler&#39;s power supply fails or refrigeration system quits working. 
         [0006]    Another aspect of the invention relates to the type and construction of the front door lock. A common type of lock will lock the door when the power is interrupted and remains locked until the power is restored and a reset condition occurs. The improvement provided will only open the door if health conditions are maintained. 
         [0007]    Another aspect of the invention relates to the construction of the latch-solenoid-lock combination that is used to lock the cooler door when health safety hazards occur. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  shows a refrigerated cooler according to an embodiment of the invention. 
           [0009]      FIG. 2  shows a health timer lock mechanism according to an embodiment of the invention. 
           [0010]      FIG. 3  shows a cooler health safety controller according to an embodiment of the invention. 
           [0011]      FIG. 4  shows the door latch mechanism in an open position according to an embodiment of the invention. 
           [0012]      FIG. 5  shows the door latch mechanism in a closed position according to an embodiment of the invention. 
           [0013]      FIG. 6  shows a door latch (hook) according to an embodiment of the invention. 
           [0014]      FIG. 7  shows a schematic assembly of the cooler according to an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0015]      FIG. 1  shows a cooler  10  according to an embodiment of the invention. The cabinet  12  is durable and is made of high density material, foamed-in-place; one-piece cabinet  12  provides maximum degree of structural integrity. The standard configuration has 6-shelves with a full-length glass cooler door  13 ; there are also models with 5-shelves. Not visible in  FIG. 1  are shelves equipped with beverage can/bottle guides, as is known in the art. 
         [0016]    The cabinet  12  is built strong such that multiple coolers  10  can be stacked three high thereby optimizing inventory storage space. Grills  14  are made of heavy gauge steel for durability. 
         [0017]    The cabinet  12  is easy to maintain. The cooler  10  further comprises a refrigeration module capable of easily be sliding in and out for ease of cleaning and replacement. 
         [0018]    Ideally, a temperature control for controlling the internal temperature of the cooler  10  is not visible to a loader or customer, discouraging unnecessary adjustment. 
         [0019]    Illumination lamps are provided that include illumination lamp shields that protect packaged food in the cooler  10  in case of accidental lamp breakage. 
         [0020]    There is no exposed wiring on an outside surface of the cooler  10  to optimize safety and cosmetic appearance. 
         [0021]    The grill  14  covering the refrigeration module is easy to remove and replace for cleaning and servicing access. 
         [0022]    The refrigeration system module  16  is located behind the grill  14  and is visible in  FIG. 3 . Cooler operation and the refrigeration cycle is controlled by a health safety controller  18  located next to the refrigeration system module  16  and is visible in  FIG. 3 . Temperature sensors  20  located inside the cooler  10  monitor the ambient temperature and report it to the health safety controller  18 . If the ambient temperature inside the cooler  10  rises above a threshold temperature or if the ambient temperature inside the cooler  10  rises above a threshold temperature for a predetermined amount of time, the health safety controller  18  will lock the cooler door  13  such that the food is inaccessible to a customer. The cooler  10  further includes a sensor  40  that detects whether the door  13  is open or closed. 
         [0023]    Referring to  FIGS. 5 and 6 , the cooler further includes a lock mechanism  30  is mounted to the cooler  10  and has a latch arm  32 . The latch arm  32  is controlled by a solenoid  34  that is controlled by the health safety controller  18 . The latch arm  32  can be operated to engage a catch  36  mounted to the door  13  to lock the door  13  in a closed position. When the solenoid  34  is energized, the latch arm  32  is lifted, thereby unlocking the door  13 . When the solenoid  34  is de-energized the latch arm  32  is lowered to engage the catch  36 . In this manner, when the cooler  10  loses power, the door  13  becomes locked. Alternatively, this operation could be reversed so that the cooler door  13  remains unlocked when the cooler  10  loses power. 
         [0024]    Alternatively, the solenoid  34  may be powered with a voltage of (+) polarity to close the lock and a voltage of (−) polarity to open the lock. If there is no AC power the solenoid will lose power and will close the lock. The only disadvantage of this construction is that the solenoid will have to continuously sustain 100% of the power; it will have to be a 100% duty cycle solenoid. 
         [0025]    If the solenoid  34  function is limited to only latch the lock in the open or closed position the power requirement for the solenoid is much less restrictive and require a more economical solenoid. However, in case of total AC power loss a relatively small power storage means like a capacitor or dc power supply (battery) will be needed in order to pulse the solenoid accordingly. 
         [0026]    A safety release button  38  is further provided that allows person who has become trapped in the cooler to open the cooler door from the inside if the cooler door becomes locked while a person is inside. Further, optionally, a key lock  40  ( FIG. 2 ) may be provided which allows a person to open the cooler door  13  from the outside with a key should the door become locked by the latch arm  32 . Such access would allow authorized individuals access to the cooler  10 , such as in the case of power failure. 
         [0027]    An external release may also be provided for use when supply power is lost to the cooler  10  and access to the inside of the cooler  10  is necessary. To use the external release, one may insert an object, such as a pencil or similar object, into an access hole located on the back of the lock assembly and angle the pencil upward, then push down to release operate the latch arm  32 . 
         [0028]    The health safety controller  18  operates the solenoid  34  that locks the cooler door  13  that prevents customers from taking food items out of the cooler if the cooler temperature rises above a certain temperature, for example 41 degrees Fahrenheit for a predetermined period, following FDA and NSF guidelines for potentially hazardous prepackaged foods. The health safety controller  18  includes a specialized circuit or processor, software algorithms and logic for monitoring temperature and activating the lock, for example utilizing relays to operate the solenoid  34 . 
         [0029]    In special cases, the safety controller software algorithm allows for loading the cooler without activating the lock in the event of excessive temperature rise. 
         [0030]    A display can optionally be provided to facilitate service personnel setting up the conditions for the health safety controller  18 , like temperature limits and durations. The display can be as simple as an LED display or an alphanumeric/images/audio capable display. 
         [0031]    The display can also be used to inform the customer of the cooler&#39;s  10  status. This may be important when the cooler door  13  is locked for a health issue. 
         [0032]    The cooler  10  and cooler door  13  can optionally be provided without the lock of  FIGS. 4 and 5 . If there is no lock, the health situation will only be indicated on the display and an audio enunciator may optionally sound. If there is a lock, the door will be locked any time a pre-registered health situation occurs. 
       Health Safety Controller Operation 
       [0000]    
       
         
           
             1. When the health safety controller  18  is first powered up, a health safety error will occur and will be displayed on the display (if there are only diagnostic LEDs, the LED will be used to indicate the error) and the door solenoid will be supplied with a signal to lock the door. This is intended to prevent access to spoiled food or drinks whenever the previous state of the refrigeration is unknown. 
             2. To reset the health safety error, the service personnel will press a RESET switch. This will clear all errors, supply a signal to the solenoid to unlock the door and initiate a timer. 
             3. Upon reset, the controller will enter a “grace” period. At the end of this grace period, the controller will sample the cabinet temperature to see if the temperature is below a predetermined temperature, such as 41° F. (5° C.). The length of this grace period is determined by the state of the door switch at the time the reset button is pressed.
           a. If the door is open at the time of reset, the controller will allow a first grace period, for example a 60-minute grace period.   b. If the door is closed, the controller will allow a second grace period, such as a 30-minute grace period.   c. If at the end of the applicable grace period (for example, 30 or 60 minutes) the temperature is not below the predetermined temperature (for example, 41° F. (5° C.)), the controller will trigger a health safety error and signal the solenoid  34  to lock the door and signal the display and/or diagnostic LED to indicate a health safety error.   
         
             4. The health safety controller  18  constantly monitors the cabinet temperature. After the initial grace period has expired, the controller will assume normal operation and watch for an unexpected rise in temperature.
           a. If the temperature is observed to rise above a predetermined temperature, such as 41° F. (5° C.), the health safety controller  18  will start a timer for a predetermined amount of time, such as 15 minutes.   b. If the temperature remains above the predetermined temperature for more than the predetermined timer length, the health safety controller  18  will trigger a health safety error and signal the solenoid  34  to lock the door  13 .   c. If, within the predetermined timer period, the temperature returns below the predetermined temperature, no health safety error will occur.   
         
             5. The health safety controller  18  constantly monitors the state of the door switch. If the controller  18  determines that the door switch has cycled (i.e., gone from closed to open or open to closed), the controller will begin a grace period. The length of this grace period will depend upon the state of the door after the transition has occurred.
           a. If the door is open after the transition, the health safety controller  18  will allow a predetermined grace period, such as 60 minutes.   b. If the door is closed after the transition, the controller will allow a second predetermined grace period, such as 30 minutes.   c. If the door again cycles during the grace period, the grace period will be reset and the countdown will be based upon the state of the door switch based on rules (a) or (b) above.   d. At the end of the grace period, the cabinet temperature must be at or below the predetermined temperature. If the temperature is above the predetermined temperature, a health safety error will be triggered, the solenoid will be signaled to lock the door and an error will be indicated on the LED an/or display. If the temperature is at or below the redetermined temperature, normal operation will resume.   
         
             6. Optionally, the health safety controller  18  further monitors supply power to the cooler  10  with a supply power detector circuit. When supply power is disrupted, the controller will shed all loads (LEDs, sensors, etc.) and signal the solenoid (from a capacitor or battery) to lock the door  13 , and the health safety controller  18  will enter into a low-power state of operation. The controller  18  will remain in this low-power state for a predetermined period time, for example 30 minutes, or until AC power returns. If AC power returns before this predetermined period of time has expired, the controller will sample the temperature upon power-up.
           a. If the temperature is at or below the predetermined, the controller will return to normal operation and signal the solenoid  34  to unlock the door  13 .   b. If the temperature is above the predetermined temperature, the controller will trigger a health safety error and signal the solenoid to lock the door (to ensure the door is still locked).   c. If power is not restored within the predetermined time period, the health safety controller  18  will trigger a health safety error.