· domestic rooftop evaporative airconditioners that are also marketed under the brand name "Breezair".
25 Thus it can be said that Seeley manufactures two types of domestic airconditioning units. The first of them is the "Convair" standard portable unit ("the portable unit"); it is free-standing and can be moved from place to place. It is powered by connecting it to an ordinary electric power socket; it carries its own water reservoir and, when it is operational, it pumps cool air into a room. Seeley has manufactured that type of cooler for many years. These proceedings are not concerned with the portable unit, although it will be necessary to refer to it from time to time when discussing the history of Seeley. The second unit is the "Breezair". The domestic rooftop version of this brand is the unit with which these proceedings are concerned. Hence, any reference hereafter to "Breezair" will refer only to a Seeley's domestic rooftop evaporative airconditioner. It is much larger than the portable unit and, when used for a conventional house property, it is installed on the roof of the house.
26 The Breezair operates on the principle of water cooled air. Inside the external cabinet (or housing structure) there is an evaporative media that is affixed to the four vertical sides of the cabinet. Initially, this media was "woodwool" but later a cellulose based medium that is called "CELdek" was used. A water distribution system is used to pump water from a holding tank in the bottom of the unit to a water spreader at the top of the unit. At the top of the unit the water spreader evenly distributes the water so that it is able to flow by gravity feed down the CELdek, thereby wetting the evaporative media. The water distribution system includes both inlet and outlet valves that are used to dump and replace old water in the tank. These valves were initially operated by electrically controlled devices called actuators. Mr Frank Seeley, the chairman of directors of the applicant, during the course of his evidence, described an actuator as something akin to a cylinder with a piston. He likened it to a bicycle pump. In a particular operation it would be as though the handle of the pump was extended and in the next phase the handle was driven, as if a piston, into the cylinder. There are two actuators in the system. One of them activates the opening of the dump valve and the other operates "to activate the closing of the water in that valve". A large plastic centrifugal fan is located inside the cabinet and is used to draw air from outside the cabinet through the wet evaporative media (the CELdek) thereby cooling the incoming air. The fan then drives the cool air through an outlet at the bottom of the cabinet into the duct work and, from there the cool air is pushed into the internal rooms of the house. The unit operates by means of an electric motor which drives the centrifugal fan; a belt and pulleys are attached to the motor and the fan axle.
27 The Seeley business commenced in 1967 as a partnership between Mr Frank Seeley and his brother, Cedric. Initially, its activities were limited to the retailing of "Coolair" portable evaporative airconditioners. In the first year of operations, the business was that of an assembly operation. The components that were used in the cooler were manufactured by other business houses and Messrs Seeley and their workforce merely assembled and sold them. Mr Cedric Seeley died in 1969. For a short time, Mr Frank Seeley continued the business with his brother's widow, but then in 1972 Mrs Cedric Seeley sold her interest in the business to Mr Frank Seeley and his wife, Mrs Kathy Seeley. Subsequently, corporate changes have occurred and now the business is owned and operated by the applicant, a corporation, the shares in which are beneficially owned by members of the Frank and Kathy Seeley family.
28 It was in about 1972 that the business switched from mere retailing to the manufacture of portable units. Mr Seeley, during the course of his evidence, explained that he developed a prototype portable cooler that was based on existing coolers save that he changed it, wherever possible, from a metal based product to one which, apart from its electrical components, was made almost entirely from plastics. Existing brands had been metal-based products and the use of water in the evaporative system meant that they were liable to corrode; his use of plastic was a substantial innovation. He sold about 1,000 units in his first year but in 1981, after ten years, the business had manufactured and sold about 150,000 portable evaporative air coolers. By 1976, the business was employing about 100 employees and in 1978 it started to supply Email Ltd with portable units that Email marketed under the badged name "Email Air".
29 In 1980, the business obtained an export order to supply Iraq with 40,000 portable units. According to Mr Seeley, the business sold a total of 70,000 portable units or thereabouts in Australia and Iraq that year with a turnover of approximately $10 million. It was also in 1980 that the business expended about $1 million in plant and equipment so that it might thereby be able to manufacture its own electric motors for its portable coolers. During 1980, further improvements were made and, as a result, more "air delivery" was achieved from the cooler. Noise level was reduced by 50 per cent and power consumption was cut by about 10 per cent. In 1981, the business obtained a further order from Iraq for 100,000 portable units. As the cost to the business of manufacturing its own motors had achieved a saving of about $10 per unit, the business recouped its capital investment in the new plant and equipment within a year or so. It also redesigned and reworked its product, reducing it from 389 components to 56 components. This was achieved, in the main, by the use of plastics and, in particular, plastic clips which were designed to replace metal screws and fastenings.
30 Mr Seeley also said that in 1981 his company's engineers had begun working on the idea of expanding the business so that it could manufacture rooftop evaporative airconditioners in addition to the portable units. In 1982, the business was further expanded; it purchased the plant and equipment that was necessary to enable it to undertake its own plastic injection moulding; it was now able to make its own plastic components.
31 In 1983, Seeley entered the rooftop evaporative airconditioning market with its EA model. At that time, the market in Australia for such rooftop airconditioners was about 10,000 to 15,000 units per annum, although it grew to 25,000 units by 1989. The geographic market for evaporative coolers was and is limited to areas of dry heat; they are not particularly suitable for humid conditions. As a result, the market is centred on Perth, Adelaide, Melbourne and areas of rural Australia to the west of the Great Dividing Range.
32 Seeley's EA model had a plastic polymer cabinet, a plastic fan housing and a plastic centrifugal fan. Mr Seeley said that it had the advantages of a superior appearance, durability and resistance to corrosion because of its use of plastics and it was promoted as having these advantages. He said that it also had a significantly lower cost price and that its patented centrifugal fan was superior to the conventional propeller-type fan that was used in its competitors' models. Initially when the EA model was introduced, it was sold under Seeley's existing brand name, Convair. However, the General Electric group, which had initially been a purchaser of the EA model, decided to quit the field and Seeley took over that group's brand name, "Breezair". Seeley continued thereafter to use "Breezair" as the name for its EA model.
33 In 1983, when the Breezair EA model was introduced, the motors that were used by Seeley to drive the evaporative airconditioners were fixed speed motors that operated at mains voltage. Some could operate at two different speed levels whilst others could operate at a three speed function. In either case, it meant that the level of cooling could only be set in limited steps such as "high", "medium" or "low". The controller that was used to operate the unit was wall mounted and was connected by conventional electrical wiring to the airconditioner on the roof. The basic task of such a controller was to switch the unit "on" and "off". The controllers that were used by Seeley at that time were acquired by it from the manufacturer, a company that carried on its business under the name of "Clipsal".
34 In 1983, immediately before the introduction of the Breezair EA model, Seeley faced four major competitors in the rooftop market. Bonaire and Braemar each controlled about 40 per cent of the market, whilst Coolair and Celair each accounted for 10 per cent or thereabouts. According to the unchallenged evidence of Mr Seeley, Bonaire was based in Adelaide, as was Coolair, and those businesses sold throughout the Australia wide market. He said that the Braemar brand, which was based in Albury, sold mainly in New South Wales and South Australia, while the Celair brand, which was based in Leeton, sold mainly in New South Wales and Queensland. There were, in addition to these four major competitors, several other minor competitors throughout Australia. Despite this opposition, Breezair managed, nevertheless, to make a successful entry into the rooftop market as did another brand, Brivis, in 1986. Breezair's success may be gauged from the fact that by the end of 1989 its sales of domestic rooftop evaporative airconditioners had risen from nil in 1983 to about 12,000 units. As at 1990, it was claimed by Mr Arnold, Seeley's managing director, that Breezair enjoyed market leadership when regard was had to its market share of 43.4 per cent, to its innovative features and to the number of dealers who sold Breezair units.
35 Between 1983 and 1989, Seeley introduced further innovations to its EA domestic rooftop evaporative airconditioner. For example, in 1986 Seeley introduced variable speed motors which, as their name suggests, permitted the units to operate at a multiple range of speeds. They required variable speed controllers which Seeley also introduced in 1986. The primary function of a controller is, as I have already noted, to activate the airconditioner by turning it "on" and "off". It can, however, operate other functions of the airconditioner, including regulating the speed of the main motor and the fan; it can also be used to turn the pump motor "on" and "off" and to turn the inlet and outlet valves "on" and "off". The controller is a vital part of any evaporative airconditioner. It is important that it responds correctly to any setting that may be made by the operator. Thus, it is important that the controller not energise the motor when it has been switched "off" by the operator. It is particularly important that the controller not energise the run winding only because such energisation could cause the motor to overheat without turning and that could lead to ignition and fire. The variable speed controller was also a wall mounted switch, similar to the fixed speed controller, but with the addition of a rotary knob which selected the variable speed. Variable speed motors had the advantage of offering consumers a greater range of comfort levels. This new type of controller was then connected to a control box within the airconditioner which incorporated a triac. A triac was used to control the variable speed of the motor by regulating the voltage that was supplied to the motor (and hence its speed). This high voltage, variable speed controller was manufactured for Seeley by Tekelek Pty Ltd ("Tekelek").
36 Between 1990 and 1992, Seeley's share of the market receded. This was partly because of the activities of Seeley's competitors, including Coolbreeze, which had entered the market in 1990, and partly because of the financial difficulties that Seeley suffered as a result of the default of an international customer. In 1989, Seeley suffered acute financial embarrassment when an international purchaser defaulted in payment of about $5m. Seeley acknowledged that, for the next several years, it was in strained financial circumstances and was unable to devote significant resources to product development and innovation. Ultimately, Seeley was successful in achieving the return of its goods from the defaulting purchaser but that did not occur until mid 1992.
37 In about July or August 1992, Seeley, having overcome its financial crisis, resolved to pursue the development of a radio frequency [RF] remote control for its Breezair rooftop evaporative airconditioners. It had, in the preceding October, introduced a thermostatic electronic control with a liquid display known as "the Sensortouch" for the summer of 1991-1992. As I have already noted, Seeley's rooftop airconditioners were then controlled by a wall-mounted "hard-wired device". In the early 1990's, those devices were still only available with one of two options: a customer could have a Clipsal "on/off" switch with two speeds or he or she could have the variable speed switch that was made by Tekelek. It was said, on Seeley's behalf, that its decision to introduce the RF remote control was one of a series of innovations that had been planned by the company to regain Seeley's market share. The evidence satisfies me, and I find that in August 1992 Seeley engaged Cintro to design and manufacture an RF remote control which was designated "the RF Sensortouch". I also find that the RF Sensortouch remote control was to have similar functions to the Sensortouch that had early been designed and manufactured by Tekelek but that it was to be a moveable hand control that operated by means of radio waves.
38 The initial task that Cintro, and later Newtronics, was to perform, was the design and manufacture of a radio frequency (RF) Sensortouch remote control prototype that would control the operation of Seeley's rooftop evaporative airconditioners. That operation was to include the method by which the motor in the airconditioning unit would be energised. The prototype was to comprise three modules:
· a hand held remote control transmitter unit; (this was known by several names such as "a radio frequency module" or "the remote control" or "the remote controller"); its technical name is an "electronic transmitting module" or an "ETM". It is a conventional handset that is now a familiar object in most homes - the type of handset that is used to control a television set or a video recorder.
· a printed circuit electronic control board with copper conducting tracks which was also called a "printed control board" or a "PCB". It was to be installed inside the rooftop evaporative airconditioner; (this item is sometimes referred to as the evaporative cooler control module or "the ECCM"; it is also known as "the power board"); and
· a receiver located in the roof space of the premises and fitted as part of the airconditioner; ("the receiver").
39 The system that Cintro was to design for Seeley was to have a variable speed control that could be used through the remote control system; it was intended that it would replace the wall-mounted hard-wired variable speed control system.
40 A plastic box was to be mounted on the fan scroll which was inside the housing of the rooftop unit; it was to be connected by a lead to the radio receiver. The box was manufactured in two halves which fitted together. The top section, sometimes called "the lid", was to hold the evaporative cooler control module ("the ECCM" or "the power board"). The purpose of the ECCM was to receive and interpret transmissions from the ETM and to provide control and power for all functions of the cooler. The receiver was to be mounted in the roof to receive the radio signals from the handset, that is the ETM.
41 Seeley was to receive deliveries of the separate components from Newtronics - those components being the handset or the ETM, the ECCM and the radio receiver. Seeley would then incorporate those components in its assembly of the end product. This involved the installation of the ECCM in the lid together with various other components such as the heat sink and mylar insulating sheets for which Seeley was responsible.
42 By facsimile transmission dated 11 October 1993, shortly after the date when Newtronics took over the business Cintro, Mr Ray Cox submitted to Seeley details of the price per unit for the supply and delivery of the ECCMs and the ETMs.
43 By 1993, Seeley was in a position to launch a new rooftop model - the EM model. It was intended that it would have the RF Sensortouch remote control feature that Cintro had been retained in 1992 to develop, but Cintro had not been able to meet Seeley's deadline. I am satisfied that the EM model can properly be described as innovative: it had a rounded lower profile together with a new special feature called "the no seasonal maintenance"; that involved the inclusion in the rooftop system of an automatic weather seal. Until then, all rooftop airconditioning units suffered the drawback that, as they were designed to admit air in the summer, they were prone to admitting cold air into the ducting system in the winter. The only solution was to climb on to the roof and cover the unit at the end of summer and uncover it at the end of winter. Seeley's automatic weather seal avoided that; Seeley had designed an internal seal that could be locked in place by the use of an electronic device. The EM model, which came in various sizes and capacities was fitted with a variable speed motor which was controlled by the variable speed controller. The unit consisted of a plastic housing with vented sides to admit air into the housing; in fact, the unit was almost exclusively made of plastic injected moulding apart from the electrical componentry and a few other items, such as a steel axle. The large cylindrical centrifugal fan was also made by means of injection moulded plastic. Seeley claimed that its centrifugal fan had three advantages over a metal axial fan; first it could move the same volume of air as a much larger axial fan; secondly it was quieter in its operation than an axial fan and thirdly, it was much cheaper to produce. I accept that these features were well ahead of Breezair's competitors.
44 The new EM model was released in October 1993 in time for the 1993-1994 summer season, but it was September 1994 before Seeley was able to release the RF Sensortouch remote control for use with the EM Model.
45 As from September 1994, a Seeley EM model could be purchased with one of three controlling devices. The first option was a hard-wired wall-mounted, variable speed controller that had been designed and manufactured by Tekelek. The second choice was a hard-wired, wall mounted Sensortouch electronic controller which included both an automatic temperature regulating function and a variable speed control function. That had also been designed and manufactured by Tekelek and it employed a triac to regulate voltage and, consequentially, power to the motor. In September 1994, however, Seeley was able to offer the third alternative - a radio frequency (RF) Sensortouch remote control. Its design had been commenced by Cintro and concluded by Newtronics. Newtronics was its manufacturer. Basically, it had the same functions as the wall-mounted Sensortouch controller, save that it had the huge advantage of being a hand held unit that was capable of being carried from place to place. It was an immediate success and Seeley achieved very substantial sales in the summer to January 1995. But then, in the space of four days in February 1995, the three fires occurred in three EM rooftop units. Each of them had been installed with a system that had been designed and supplied by Newtronics.
46 The Seeley motor which was used in the EM model was described by one of Seeley's expert witnesses, Professor Bonwick, as a "single phase induction motor connected through circuitry to mains supply electricity". Elsewhere in a report that he produced, he said of the motor that it was a "Permanent Split-Phase Capacitor" motor, the word "Permanent" referring to the fact that the start motor always remains connected. It comprised a stator and a rotor. In the finished product, the rotor was installed inside the stator and rotated with a very small clearance. The stator was manufactured with a series of slots that were arranged around it in a diameter. Those slots contained turns of copper conducting wire. The Seeley motor had two windings - the start winding and the run (or main) winding. The start winding was arranged so that it traversed the ends of the stator that were closest to the outer perimeter of the stator, whilst the run (or main) winding was arranged so that it traversed the ends of the stator that were closest to the inner perimeter. In each case, the windings were turned in four symmetrical sections known as poles. The principal purpose of the start winding was to create a rotating magnetic field through the space that was occupied by the rotor. It thereby subjected the rotor to a rotating force of sufficient power to cause it to turn from a stationary position. When a passage of alternating current was passed through the run winding and the stator, it created a pulsating magnetic field. As the rotor sat in the path of that magnetic field, it became magnetised and so induced an electric current in the rotor.
47 The start winding was to be connected by Seeley personnel to the mains supply through a mechanical relay or switch. The relay was to remain open and non-conducting until it received a signal that was initiated by pressing the "on" button on the remote control handset. That action would send a signal to the micro-processor which activated a low voltage circuit that passed through the winding coil; that, in turn, caused the switching arm to be drawn across to the connecting contact, thereby closing the start winding circuit and so activating the AC supply and connecting the start winding.
48 Two of the principal components in the run winding circuit were the opto-coupled triac and the main (or power) triac. The circuit employed the opto-coupled triac to control the speed of the air-conditioning fan; it was also intended that it would block or isolate the mains supply from the run winding when the motor was not energised - that is, when it was intended that the motor be turned "off".
49 The motors for the rooftop airconditioners came in a variety of sizes, the smallest of which was 370W. The largest of the motors was 1500W but the evidence in these proceedings only referred to the 750W, the 1100W and the 1500W motors. The axle for the motor was made out of a section of rectangular stainless steel; it passed through a connecting section in the middle of the fan, enabling the axle to grip and turn the rotating fan. The unit had a plastic pulley that was so constructed that it was possible to adjust the diameter of its surface and the tension on the pulley belt. Using an instrument known as a tong meter, an installer could measure the current that was drawn by the motor under normal operating conditions and then adjust the pulley to achieve the optimum current, and hence, the optimum output of the motor. This ensured that the motor was not overloaded to the point of overheating under normal operating conditions.
50 The design, manufacture and operation of the RF Sensortouch remote controllers is at the heart of this case. Seeley's case includes the allegation that the controllers that had been used and installed in each of the units that were involved in the house fires had been designed by Cintro and Newtronics and manufactured by Newtronics. Seeley has alleged that they caused the fires and that Cintro and Newtronics were negligent in the design and that Newtronics was negligent in the manufacture of the controllers.
51 As a result of the fires Seeley had to institute a nationwide recall ("the recall") of all its RF Sensortouch controllers; it started this on 17 February 1995 by contacting its dealers and known purchasers. Emergency action was taken to isolate all units so that they were no longer attached to the mains power. At a later stage, owners were provided with an alternative, safe, control mechanism so that they could operate their units. Later again, owners were given the option of having better control units installed or keeping their existing control units and waiting until the remote control system was redesigned and available for use.
52 The business that had been commenced by Mr Seeley and his brother in 1967, and which is now conducted by the applicant, has grown from a modest annual turnover of $100,000 to its present turnover of many, many millions of dollars. The applicant has claimed that this substantial increase in the size of the business has been the result of its corporate energy and its commitment to innovation; it has also claimed that it has always been a market leader and an innovator. However, Seeley has further claimed that, because of the three fires in February 1995 and the recall, its reputation has been seriously damaged; it had to wind down its research and development; its capacity to innovate was, so it has claimed, substantially impaired and it lost a large part of the market share. According to Dr Beaton, Seeley's market share was materially reduced. Dr Beaton, an expert in marketing, gave evidence about the impact that the three fires and the recall had on Seeley's business and its reputation.