Field of the invention

[001] The invention relates to a collapsible housing design for insulated food storage cabinets, including insulated food storage cabinets for use in a supermarket setting. The invention also relates to an assembly kit for a collapsible housing for an insulated food storage cabinet.

Background of the invention

[002] In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date, publicly available, known to the public, part of common general knowledge; or known to be relevant to an attempt to solve any problem with which this specification is concerned.

[003] Whilst the following discussion is in terms of a housing for insulated food storage cabinets for use in supermarkets, a person skilled in the art will appreciate that the invention is not so limited and may be applied for non- supermarket applications. Likewise when the term "food" is used herein, it encompasses beverages as well.

[004] Insulated food storage cabinets are commonly used for refrigerated food but may also be used to store food. They are used to display perishable, cooled or heated products which require storage at a controlled temperature. Such products include meat products, dairy products, deli products, fruits, vegetables, some processed food, drinks, hot food and frozen food.

[005] Insulated food storage cabinets are insulated as much as possible to maintain the integrity of the food contained in them. In the case of insulated food storage cabinets for storing frozen products, it is usual for them to have thick, vacuum-sealed doors to prevent the entry of warm air which could raise the temperature and adversely affect the contents. The less uncontrolled air that enters the cabinet, the more controlled the temperature is inside the cabinet and the less it costs to maintain the desired temperature.

[006] If the insulated food storage cabinet is a store display cooler, then the ability to control the temperature is more limited. Some display insulated food storage cabinets have sliding glass doors that are poorly insulated, and are constantly opened and closed by customers and employees, which substantially decreases their efficiency. Other display insulated food storage cabinets are open fronted. Such display insulated food storage cabinets need powerful refrigeration and/or heating systems to keep the products at desirable temperatures.

[007] In a setting, such as a supermarket, there may be a central unit which comprises a refrigeration system for all of the insulated food storage cabinets in the building.

Alternatively, individual cabinets may have their own refrigerant or cooling systems. Where there is a remote or centralised refrigerant or cooling system, the individual insulated food storage cabinets only need to contain an evaporator and fans. For the supermarket setting, the evaporator and fan assemblies are often located in the base of the housing.

[008] Currently, housings for insulated food storage cabinets differ depending on their application (refrigerator or freezer) and so they are typically manufactured separately to suit that specific application. There are housings for low temperature applications

(typically operating at around -25 °C) which are typically accessed by a closable sealed door, such as those for storing frozen food. Separately, there are housings for medium temperature application (typically operating at around +4°C), such as those for displaying unfrozen meat and dairy products.

[009] Typically, these insulated food storage cabinets are prefabricated modular units, assembled at a manufacturing facility. They are then transported to the installation site where they are installed directly without the need for further assembly. Such housings (being finished products) take up large amounts of transport volume and are expensive to transport (eg a limited number of these finished insulated food storage cabinets may be shipped in a standard shipping container or on a truck).

[0010] Alternatively, housings for insulated food storage cabinets may be transported as separate components (ie unassembled or partially assembled) which enables more of them to be shipped for transport in a standard container. Assembly of these cabinets is carried out or completed on site.

[0011] Typically, the final assembly of the cabinet is performed at a facility remote from the installation site. Further, assemblers of the insulated food storage cabinets require particular training, especially as the integrity of the insulated food storage cabinet is dependent upon achieving sealing/insulation relationships between a number of the components. Quality control of assembly is best achieved by standardising the assembly process. Typically, this has reinforced the practice of centralised assembly before transport notwithstanding the added transport cost.

[0012] Alternatively, skilled assemblers are needed at the point of installation which increases the cost of assembly (eg travel time, location/duplication of assembly tools remotely and lack of testing facilities).

[0013] Accordingly, there is a need for a housing for insulated food storage cabinets which is relatively simple and adapted to be economically manufactured, transported, assembled and installed.

Summary of the invention

[0014] According to a first aspect of the invention, there is provided a housing for an insulated food storage cabinet comprising:

(a) a base having a lower member and at least one wall extending upwardly from the lower member to define a upwardly open cavity;

(b) at least one wall support extending upwardly from the base; and

(c) at least two insulation panels assembled together to define an insulation wall engaging the at least one wall support, wherein one insulation panel abuts and sealingly engages an adjacent insulation panel.

[0015] Preferably, the housing further comprises a cover member to cover the upwardly open cavity.

[0016] Preferably, the insulation wall defines a back wall and roof of the housing.

[0017] Preferably, the housing further comprises end or side insulation walls connected to the insulation wall when required to form an open fronted enclosure. Where a closable cooling cabinet is needed (eg to store frozen foodstuffs), at least one door may be connected to the housing to close the open front. That connection will typically be a pivotal connection or a sliding connection upon guide tracks. [0018] Preferably, the adjacent panels abutting each other are connected to permit pivotal movement between a first position where the panels are not coplanar to a second position where the panels are coplanar. Typically, the connection between adjacent panels is a flexible member and/or a fixed hinged member.

[0019] Preferably, the adjacent panels are provided with complementary locators to fix adjacent panels in coplanar orientation. Typically, one of the panels would be provided with a groove or set of holes and the adjacent panel would be provided with

complementary projections to locate in the groove or holes.

[0020] According to a second aspect of the invention, there is provided an assembly kit for a housing for an insulated food storage cabinet comprising:

(a) a base having a lower member and at least one wall extending upwardly from the lower member to define a upwardly open cavity;

(b) at least one wall support; and

(c) at least two insulation panels located in and/or on the base and movable to a position engaging the at least one wall support in which position one insulation panel abuts and sealingly engages an adjacent insulation panel.

[0021] Preferably, the at least one wall support is movable from a first position located in and/or on the base to a position extending upwardly from the base.

[0022] Preferably, the adjacent panels to abut each other are connected to permit pivotal movement between a first position where the panels are not coplanar to a second position where the panels are coplanar. Typically, the connection between adjacent panels is a flexible member and/or a fixed hinged member. Preferably, the pivotally connected panels are concertinaed against one another and located in and/or on the base.

[0023] Preferably, the adjacent panels of the assembly kit are provided with

complementary locators to fix adjacent panels in coplanar orientation. Typically one of the panels would be provided with a groove or set of holes and the adjacent panel would be provided with complementary projections to locate in the groove or hole.

[0024] The housing according to the various embodiment of the invention is simple in design and simple to assemble avoiding the need to have highly skilled assemblers. As the insulation wall is made up of a number of panels, which are typically of common length but may have common or different depth, it is possible to fabricate housings of different heights or widths using a modular approach. The base is typically designed so that at least some of the insulation panels may be stored in the base. Similarly the wall supports may be stored in the base. As such, the invention is adapted to providing the assembly kit as a flat pack meaning that transport costs may be significantly reduced.

[0025] Further preferred features of the various aspects of the invention are now discussed.

The base

[0026] Typically, the base having a lower member comprises four walls. The walls may have equal or different dimensions. Typically, opposed pairs of walls are parallel to each other.

[0027] The base may further comprises a drain adapted to collect liquid and other materials which collect in the base of the cabinet. Typically, the inner surface of the lower member slopes towards the drain to encourage drainage.

[0028] Typically, the lower member of the base has a substantially flat outer surface destined to lay on a flat floor of the supermarket or similar venues.

[0029] Preferably, the base is a single integral component. Typically, the base is constructed from steel components with foam insulation, but may also be constructed using other materials such as plastic and insulated by a vacuum.

[0030] In the case of a cooling cabinet, the cavity of the base is typically adapted to receive one or more evaporators and one or more fans. The evaporator is adapted to cool the air circulating in the refrigerated insulated food storage cabinet and the fans circulate air through the evaporator assembly into the refrigeration space of the refrigerated insulated food storage cabinet. The evaporator and fans may be any suitable evaporator and fans used in refrigeration applications. Typically, the fan is mounted in the cover member.

[0031] The insulation wall comprises at least two insulation panels which are adapted to be assembled together and directly or indirectly engage the at least one wall support. Typically, the panels may be rectangular and have a common length, but may have common or different depth. In this specific arrangement it is possible to fabricate housings of different heights (horizontally orientated panels) or widths (vertically orientated panels) using a modular approach. In a preferred embodiment, the insulation panels are 1875 mm x 2500 mm x 3750 mm in size.

[0032] The insulation panels are adapted to be assembled adjacent to each other and when assembled, may be orientated substantially horizontally or substantially vertically adjacent to each other. When assembled, adjacent edges of the insulation panels are connected using any connectors. In a preferred embodiment, the connectors are hinges. It will be understood that adjacent edges of the insulation panels must be complementary in shape to enable the sealed connection. Preferably, the edges are substantially

straight/planar.

[0033] Typically, the insulation panels will be made from a sandwich construction using metal outer panels with an insulating core. The construction may also be completed using an enclosed moulded body using insulating core material or vacuum.

Roof insulation panel

[0034] In one preferred embodiment, the housing further comprises a roof formed from the insulation panels or supplied separately of the insulation panels. However, it will be understood that this may not be needed when the housing is inserted into a cavity which has a roof having adequate insulation properties.

[0035] The roof insulation panel typically extends substantially perpendicularly to the rear insulation wall. The roof insulation panel is typically movable from a collapsed position against the other panels during transport to an erect position once installed so as to extend perpendicularly from the rear insulation wall.

[0036] Preferably, the roof insulation panel is rectangular. Typically, the roof insulation panel has the same length as the insulation panels of the rear insulation wall. The roof insulation panel may have equal or different width and thickness as the insulation panels of the rear insulation wall. The wall support

[0037] The wall support may be any appropriate wall support that can be used to support a wall in an insulated food storage cabinet. Examples of appropriate wall supports include elongated members having a first end for fixing to the base. The elongated member may be fixed to the panels at any desired locations using conventional fixing means.

Where a roof will form part of the housing, the elongated member may be provided at its other end with a projection to support and enable the roof to be fixed in position.

Preferably, the projection extends substantially perpendicularly to the elongated portion of the member.

[0038] Preferably, the wall support may be stored in the base (collapsed position) during transport from the manufacture site to the installation site. Once at the installation site, the wall support is removed from the base and connected to the base in an erect position extending upwardly from the base.

Side or end insulation walls

[0039] The housing may further comprise one or more side or end insulation walls comprising one or more side insulation panels. Typically, the side insulation wall extends perpendicularly from the base and perpendicularly to the rear insulation wall. Typically, the bottom edge of the bottom side insulation panel is connected to the lower edge of a side wall of the base, if the insulation panels are oriented horizontally. The bottom edge of the bottom side insulation and top edge of a side wall of the base may be connected by any means known in the art.

[0040] Typically, the side insulation wall is connected to one or more side wall supports.

Side wall supports

[0041] The side wall support(s) may be any appropriate wall support that can be used to support a wall in an insulated food storage cabinet. Typically, these supports will have the same or similar features of the wall supports and engage the base in a similar way. Doors

[0042] In one preferred embodiment, the housing further comprises doors. Doors are typically used when it is desired to use the housing for low temperature applications or when it is desired to reduce energy consumption.

[0043] Typically, the doors are connected to one or more door supports. These will conventionally be sets of hinges to permit pivotal movement of the doors relative to the housing or guides to permit sliding movement of the doors relative to the housing.

Display fittings

[0044] The housing further comprises one or more display fittings adapted to accommodate items to be cooled or heated. Typically, the display fittings are connected to the rear insulation wall using bracketing but in some instances the fitting may not be required.

Post assembly of the cooling cabinet

[0045] In a preferred embodiment, a sealant may be applied between the adjacent pairs of edges of the various walls and panels when the insulated food storage cabinet is or has been assembled. The sealant may be any suitable sealant for use in refrigeration applications. Examples of suitable sealants include mastic, foam or similar.

[0046] Typically, the insulated food storage cabinets of the present invention once assembled are connected through piping to a refrigeration system comprising a refrigeration circuit. Such refrigeration circuits typically comprise compressors and condensers/heat exchangers. Examples of suitable refrigeration systems include those described in Australian provisional patent application number 2010902416, Australian provisional patent application number 2010902417 and Australian patent application number 2006200241.

[0047] The housing for an insulated food storage cabinet according to the various aspects of the present invention described provides a number of advantages including:

(a) improved energy efficiency; (b) they do not require total prefabrication before delivery on site and can easily be installed on site without the requirement of specialist engineering means;

(c) they are adaptable for use in both low and high temperature applications;

(d) the kit assemblies for a housing is adapted for flat packing and stacking;

(e) improved access through standard door openings;

(f) reduced shipping damage due to internal storage of components;

(g) reduced transport cost;

(h) improved safety from greater handling stability of flat pack;

(i) reduced wrapping material for packing; and (j) improved access for installation piping.

Brief Description of the Drawings

[0048] The present invention will now be further illustrated with reference to the accompanying drawings. It will be understood that the invention is not restricted to the embodiments shown which are provided by way of example only:

[0049] Figure 1 is a drawing of a perspective view of a flat pack version of a housing according to the invention.

[0050] Figure 2 is a perspective view of a partially expanded view of the housing of Figure 1.

[0051] Figure 3 is a perspective view of an expanded view of the housing of Figure 1 with the rear insulation wall completely extended with a roof panel in place.

[0052] Figure 4 is a perspective view of the housing of Figure 1 with a wall support erected.

[0053] Figure 5 is a perspective view of the housing of Figure 1 with shelves installed.

[0054] Figure 6 is a cross sectional view of the base of the housing of Figure 1. Detailed description of the embodiments

[0055] One form of the invention is shown in the drawings. In Figure 1, housing 10 for an insulated food storage cabinet is in a collapsed (or flat pack) form which may be readily and efficiently transported. Housing 10 comprises base 20, rear insulation wall 30 and roof insulation panel 33.

[0056] Base 20 comprises a cavity 21 (see Figures 2 and 6), a lower member 22 and walls 23, 24, 25 and 26. Base 20 is connected to channel 27 which provides support for the base 20. Holes may be provided for refrigeration piping.

[0057] Rear insulation wall 30 comprises two insulation panels 31, 32. Wall 23 of the base 20 is connected to the bottom insulation panel 31 using a hinge. The bottom insulation panel 31 is connected to top insulation panel 32 using a hinge and the top insulation panel 32 is connected to roof insulation panel 33 using a hinge. Typically one or more of these hinges may be full length hinges.

[0058] In Figure 2, the insulation panels 31, 32 have been partially extended to begin forming rear insulation wall 30. Roof insulation panel 33 has also been partially extended.

[0059] In Figure 3, the insulation panels 31, 32 have been completely extended to form a vertically rear insulation wall 30. Roof insulation panel 33 is also in position.

[0060] In Figure 4, wall supports 41, 42, 43 and 44 are connected to base 20, rear insulation wall 30 and roof insulation panel 33. Typically these may be pivotally attached to the base so all that is needed is to rotate them into an upright position.

[0061] In Figure 5, shelves 50, are connected to wall supports 41, 42, 43, 44 using conventional shelving bracket systems.

[0062] In Figure 6, base 20 is shown as a cross section. Base 20 comprises a cavity 21, a lower member 22 and walls 23, 24, 25 (not shown) and 26 (not shown). Base 20 also comprises drain 28 adapted to collect liquid and other materials which collect in the base. The inner surface of lower member 22 is sloped towards the drain 28. Base 20 comprises evaporator 60 and fan assembly 70. Fan assembly 70 comprises a panel 71 and fans 72. [0063] Accordingly, as shown the housing 10 is designed so that it may take on a collapsed or flat pack configuration. It may be erected and installed by carrying out the assembly sequence of Figures 2 to 5.

[0064] The word 'comprising' and forms of the word 'comprising' as used in this description and in the claims does not limit the invention claimed to exclude any variants or additions.

[0065] Modifications and improvements to the invention will be readily apparent to those skilled in the art. Such modifications and improvements are intended to be within the scope of this invention.