PCM Shelf Cooler Layout for Intermittent Power Merchandising
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional coolers, such as ice chests, face challenges in maintaining consistent product quality and stability due to intermittent power availability and lack of visual merchandising capabilities, leading to inefficient energy use and unstable product display.
Innovation Solution
A cooler design featuring a hexagonal shape with shelf assemblies containing phase change materials and evaporators, which circulates refrigerant to freeze the phase change material during power availability, maintaining the cooler in a chilled state for extended periods without power, and incorporates a Seebeck indicator for visual product indication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ice chests are used to maintain products cooled without reliable electrical power, then the cooler can operate without power, but the product quality becomes inconsistent and the cooler lacks visual merchandising capability
Solution Approach 1:
The patent applies preliminary action by pre-freezing phase change materials (PCMs) in the cooler before power interruptions occur. The PCMs are positioned in thermal contact with evaporator coils that freeze them during periods when electrical power is available. This preliminary freezing action ensures that the PCMs are ready to provide cooling during power outages, maintaining consistent product quality without requiring complex real-time control systems.
Solution Approach 2:
The patent utilizes phase transitions of phase change materials (PCMs) that transition from solid to liquid state as they absorb heat from products during power outages. The PCMs are selected with specific phase change temperatures appropriate for different product types (e.g., 0°C for beverages, -18°C for frozen foods). This phase transition mechanism provides reliable and consistent cooling without requiring complex active control systems.
2Duration of action of moving object
If large ice blocks are positioned at the top of a cooler to extend cooling duration, then the cooling period is extended, but the cooler becomes unstable and has a large footprint
Solution Approach 1:
The patent divides the cooling function into multiple distributed phase change material packs positioned throughout the cooler rather than using a single large ice block. These PCMs are integrated into shelf assemblies and positioned at optimal locations (front, rear, top, bottom) to provide distributed cooling. This segmentation extends cooling duration while maintaining cooler stability and reducing footprint by eliminating the need for large top-positioned ice blocks.
Solution Approach 2:
The patent transitions from vertical stacking of large ice blocks (occupying vertical space and creating instability) to horizontal distribution of multiple PCM packs throughout the cooler volume. The PCMs are integrated into shelf assemblies and positioned in multiple dimensions (front-to-rear, top-to-bottom), extending cooling duration without compromising stability or increasing footprint.
3Loss of information
If a dark cooler is used to indicate lack of electrical power, then power status is indicated, but consumer perception of product quality deteriorates and impulse purchases are not driven
Solution Approach 1:
The patent employs LED indicators that change color or illuminate to communicate cooler status and product quality to consumers. LEDs are positioned to indicate cooling operation status, temperature zones, and product availability. This visual communication maintains consumer confidence and drives impulse purchases even when electrical power is intermittent, replacing the negative connotation of a dark cooler with positive visual indicators of product freshness.
Solution Approach 2:
The patent introduces LED indicators as an intermediary communication layer between the cooler's internal state and consumer perception. The LEDs provide real-time visual feedback about cooling operation, temperature zones, and product availability, mediating the information gap that would otherwise exist during power interruptions. This intermediary communication system maintains consumer confidence and purchasing behavior.
4Duration of action of stationary object
If shelf assemblies with evaporators and phase change materials are used, then extended cooling without power is achieved, but device complexity increases
Solution Approach 1:
The patent merges the evaporator, phase change materials, and shelf structure into integrated shelf assemblies. The PCMs are positioned in thermal contact with evaporator coils within the shelf assembly framework, combining multiple cooling functions into a single integrated unit. This merging reduces overall system complexity compared to separate components while extending cooling duration through the combined thermal mass and phase change capability of the integrated assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The cooler effectively maintains products at a consistent chilled condition for longer periods with reduced energy consumption and improved merchandising visibility, even during intermittent power, by utilizing phase change materials and a Seebeck indicator for visual product indication.
Implementation Method 1
freezing the phase change material, and maintaining the cooler in a chilled condition for an extended period of time when the power is off by melting the phase change material
Implementation Method 2
freezing the phase change material, and maintaining the cooler in a chilled condition for an extended period of time when the power is off by melting the phase change material
Implementation Method 3
circulating a refrigerant about the phase change material when the power is on, freezing the phase change material
Implementation Method 4
a Seebeck indicator in thermal communication with the outer frame and the product space so as to indicate the presence of cooled products therein
Data Source
AI summary
The present application provides a cooler. The cooler may include an outer frame, a product space within the outer frame, and a number of shelf assemblies positioned within the product space. The shelf assemblies may include an evaporator and a phase change material therein.