Refrigeration – Display type
Reexamination Certificate
2002-01-31
2003-06-17
Tapolcai, William E. (Department: 3744)
Refrigeration
Display type
C062S255000, C062S256000, C062S291000
Reexamination Certificate
active
06578376
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to the refrigeration industry and, more particularly, to the field of commercial refrigeration air handlers and related methods
BACKGROUND OF THE INVENTION
In a commercial refrigeration apparatus, an evaporator is generally positioned within an interior region of a refrigeration container. For example, in a refrigeration apparatus positioned within a grocery store, e.g., a refrigeration display case having a glass door or an open refrigeration display case having no door, the evaporator is generally positioned along a bottom inner periphery of the refrigeration container. Applicant has recognized that this configuration tends to create numerous maintenance problems such as evaporator accessibility and clogging of drain lines, especially during transitions from defrost cycles. The evaporator positioned within the refrigeration container typically includes intake and output ducts. The configuration of the intake and output ducts, however, also cause maintenance problems in that they become easily clogged with various items that fall to the bottom of the refrigeration container, e.g., price tags and bits of food, during these cycles. Clogged intake and output ducts significantly decrease the efficiency of the refrigeration system.
In the case of walk-in refrigeration units, the evaporator is generally suspended from a top inner periphery of the refrigeration container. Applicant has recognized that condensation from the evaporator generally tends to accumulate especially during frost cycles, presenting various problems including potential health hazards. Another problem that exists with a walk-in refrigeration apparatus having an evaporator suspended from a top inner periphery of the refrigeration container is electrical maintenance. Electrical wiring to and from such evaporators are positioned within the refrigeration container closely adjacent a great deal of condensation which can occur during defrost cycles which often occur three to six times per day, for example, in commercial refrigeration units. The condensation can sometimes cause shorts and other electrical malfunctions, raising another potential hazard. Still another problem that exists with the walk-in refrigeration units is cleanliness and sanitation, i.e., condensation changes from defrost cycles from the suspended evaporators tends to drip onto food and other consumable items stored in the walk-in refrigeration container, causing a serious health risk.
Applicant has also recognized that another problem that commonly exists in a refrigeration apparatus having an evaporator positioned within the refrigeration container is that drain lines tend to freeze when positioned within the refrigeration container. When the condensed liquid in the drain lines freezes, it tends to expand and the drain lines can therefore sometimes burst.
Positioning components of a refrigeration apparatus exterior a refrigeration container is known as can be seen in U.S. Pat. No. 6,070,424 to Bauman et al. titled Modular Refrigeration Unit. Applicant has recognized, however, that the configuration of a condenser and evaporator positioned closely adjacent one another is highly inefficient and is not well suited for commercial applications, such as refrigeration systems for grocery stores. A more energy efficient and low maintenance refrigeration system is still needed.
SUMMARY OF THE INVENTION
With the foregoing in mind, the present invention advantageously provides a more efficient refrigeration system and apparatus, a more efficient evaporator apparatus, a refrigeration apparatus conversion kit for converting existing refrigeration apparatuses into more energy and cost efficient refrigeration apparatuses, and associated methods that greatly reduces maintenance needs, enhance energy efficiency, especially during defrost cycles, and reduce various hazards associated with existing refrigeration systems and apparatuses. For example, because an evaporator is removed from the interior of a refrigeration container and placed at a location exterior to and preferably on top of the refrigeration container, significantly less energy is required to defrost or heat the evaporator for the refrigeration container. Because the evaporator is positioned outside of the refrigeration container and preferably in an insulated housing on top of the refrigeration container, less area of the evaporator to heat is required for defrost cycles which can occur about 3-6 times per day, the evaporator then uses much less energy to defrost. Accordingly, for grocery stores or other structures which contain numerous evaporators for refrigeration containers, the energy saving during defrost cycles can be tremendous.
The refrigeration system and apparatus of the present invention also advantageously identifies the source of the problems associated with sanitation and cleanliness within a refrigeration container, and solves this problem by connecting an evaporator to exterior portions of a refrigeration container. The present invention also advantageously identifies and solves the problem of cleanliness and sanitation with existing refrigeration containers by removing collected condensate from the refrigeration system before it can be introduced to an interior portion of the refrigeration container.
The present invention also identifies and solves problems associated with energy efficiency of a refrigeration system by positioning an evaporator to overlie exterior portions of the refrigeration container so that warm air residing towards an interior upper portion of the refrigeration container is readily removed from the refrigeration container and so that cool air introduced towards the interior upper portion of the refrigeration container settles towards a lower interior portion of the refrigeration container without the need of excess application of a fan motor. The present invention further advantageously identifies the source of problems associated with increased maintenance costs of refrigeration systems and provides unique solutions of providing ready access to the evaporator positioned exterior the refrigeration container such as providing an enhanced air curtain and substantially eliminating blowing streams of air. The present invention further advantageously identifies the source of the problems associated with increased maintenance costs due to increased maintenance calls required when an evaporator is positioned within a refrigeration container.
More particularly, the present invention preferably includes a refrigeration system having a plurality of refrigeration containers positioned in a predetermined area. The refrigeration system also preferably includes a plurality of thermally insulated housings positioned within the predetermined area to overlie the plurality of refrigeration containers so that one thermally insulated housing overlies one refrigeration container. Each of the thermally insulated housings preferably includes an intake and an output. The refrigeration system further preferably includes a plurality of evaporators positioned within the predetermined area and within the plurality of insulated housings between the intake and the output so that one of the plurality of evaporators is positioned within one of the plurality of thermally insulated housings to move warm air from within the refrigeration container, through an intake opening formed in the refrigeration container, into the intake of the insulated housing, over the evaporator through an output opening formed in the refrigeration container, and into the refrigeration container as cooled air. The cooled air flowing downwardly from the output opening preferably defines a cool air curtain positioned adjacent a front wall of the refrigeration container. The cool air curtain advantageously allows air to be distributed more evenly than a straight directed blow or blast of cool air and advantageously reduces damage to walls of a refrigeration container and food positioned in the refrigeration container.
The refrigeration system of the present invention
Ali Mohammad M.
Allen Dyer Doppelt Milbrath & Gilchrist, P.A.
Tapolcai William E.
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