WO2016118820A1

WO2016118820A1 - Refrigerated storage system

Info

Publication number: WO2016118820A1
Application number: PCT/US2016/014452
Authority: WO
Inventors: Garrick Mcfarland
Original assignee: Garrick Mcfarland
Priority date: 2015-01-22
Filing date: 2016-01-22
Publication date: 2016-07-28

Abstract

A refrigeration system includes an enclosure that defines a refrigerated area. An access cover is selectively securable to the enclosure for housing a cooling system in a cooling system chamber partially bounded by the access cover. The access cover is selectively removable to permit access to the cooling system without entering the refrigerated area. The refrigeration system can be a modular refrigeration system. The components are premanufactured at a first location, packaged to minimize freight volume, and assembled to form the refrigeration system at the site of deployment.

Description

REFRIGERATED STORAGE SYSTEM

FIELD OF THE INVENTION

[0001] The present application claims priority to U.S. Provisional Patent Application Serial No. 62/106,422, filed January 22, 2015, and entitled

REFRIGERATED STORAGE SYSTEM, which is hereby incorporated by reference.

FIELD OF THE INVENTION

[0002] The present disclosure generally relates to refrigerated storage systems and more particularly to a refrigerated storage system constructed for convenient maintenance and repair.

BACKGROUND

[0003] Refrigerated storage systems for storing perishable items typically include a case that holds the items and a refrigeration unit that cools the case.

Conventionally, the refrigeration unit includes mechanical systems located remote from the case and a heat absorbing system located within a refrigerated area of the refrigeration storage system. Typically the head absorbing system may include an evaporator and a fan to circulate air over the evaporator and through the refrigerated area. When perishable items are received in the refrigerated area, it blocks access to the heat absorbing system for maintenance and repair.

SUMMARY

[0004] In one aspect, a refrigeration system for storing perishable items at a cooled temperature comprises an enclosure comprising an insulated wall at least partially bounding a refrigerated area for receiving the perishable items. A cooling system for cooling air in the refrigerated area is mounted on the enclosure. An access cover is selectively securable to the enclosure for housing the cooling system in a cooling system chamber partially bounded by the access cover. The access cover is selectively removable to permit access to the cooling system without entering the refrigerated area.

[0005] In another aspect, an access cover for housing a cooling system of a refrigeration system comprises a top wall and opposite end walls configured to be secured to a refrigerated enclosure to partially bound a cooling system chamber. The cooling system is located within the cooling system chamber. The access cover is selectively removable from the refrigerated enclosure to permit access to the cooling system in the cooling system chamber.

[0006] In another aspect, a refrigerated case for use in a modular refrigeration system for cooling a refrigerated area comprises an insulated wall at least partially bounding a refrigerated zone of the refrigerated area. A cooling system for cooling the refrigerated zone is mounted on the insulated wall. An access cover is selectively securable to the insulated wall to house the cooling system in a cooling system chamber. The access cover is selectively removable to permit access to the cooling system in the cooling system chamber.

[0007] In another aspect, a method of manufacturing a refrigeration system comprises removing insulating panels from a package in which the insulating panels are laid flat against one another. The insulating panels are joined together to form at least one insulating wall of a refrigerated enclosure of the refrigeration system.

[0008] In another aspect, a method of manufacturing a refrigeration system comprises separately forming components of the refrigeration system at a first location. The separately formed components are transported in an unassembled configuration to a second location remote from the first location. The separately formed components are assembled together at the second location to form at least a portion of the refrigerated system at the second location.

[0009] In another aspect, a refrigerated display case comprises walls forming an insulated enclosure and an open bottom. The floor of the establishment in which the display case may be located forms a bottom of the display case at such time as the display case is installed at the establishment.

[0010] Other aspects, embodiments, and features will, in part, be pointed out and, in part, be apparent hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a perspective of a refrigerated storage system having one wall removed to show an interior;

[0012] FIG. 2 is a section of the refrigerated storage system with components of a cooling system illustrated schematically;

[0013] FIG. 3 is a section of a removable access cover; [0014] FIG. 4 is a fragmentary section of the removable access cover and insulating top wall of the refrigerated storage system;

[0015] FIG. 5A is an enlarged view of a portion of Fig. 4 with a ramp flow profile illustrated schematically;

[0016] FIG. 5B is like Fig. 5A with a plug flow profile illustrated schematically;

[0017] FIG. 5C is like Fig. 5A with a mixed flow profile illustrated schematically;

[0018] FIG. 6A is a schematic section of five joined access covers;

[0019] FIG. 6B is another schematic section of five joined access covers;

[0020] FIG. 7 is another fragmentary section of the removable access cover and insulating top wall of the refrigerated storage system, with air flow illustrated schematically;

[0021] FIG. 8 is a section of another embodiment of a removable access cover;

[0022] FIG. 9 is a perspective of an insulation subsystem of a modular refrigeration system;

[0023] FIG. 10 is a perspective similar to Fig. 9, illustrating brackets of a storage subsystem of the modular refrigeration system installed on the insulation subsystem;

[0024] FIG. 1 1 is a perspective similar to Fig. 10, illustrating interior panels of the storage subsystem installed on the brackets;

[0025] FIG. 12 is a perspective similar to Fig. 1 1 , illustrating shelving of the storage subsystem installed over the interior panels;

[0026] FIG. 13 is a perspective similar to Fig. 12, illustrating doors of a visualization system installed on the refrigeration system;

[0027] FIG. 14 is a perspective of the modular refrigeration system as fully assembled, except for a side of the modular refrigeration system has been removed to show a refrigerated area;

[0028] FIG. 15 is a section of the modular refrigeration system;

[0029] FIG. 16 is a fragmentary section of the refrigeration system of Fig. 1 , illustrating a secondary air curtain positioned within the access cover; and

[0030] FIG. 17 is a fragmentary perspective adjacent insulating panels of the insulation subsystem partially disassembled to reveal a cam lock fastener arrangement.

[0031] Corresponding reference characters indicate corresponding parts throughout the drawings. DETAILED DESCRIPTION

[0032] Referring to Figs. 1 and 2, a refrigerated storage system for storing perishable merchandise (broadly, items) at a cooled temperature is generally indicated at reference number 10. As will be apparent, the refrigerated storage system 10 allows for easy access to at least parts of the mechanical systems that cool the merchandise. The mechanical systems can be accessed for maintenance and repair without removing the merchandise from the refrigerated storage system 10. In addition, the refrigerated storage system 10 comprises modular subsystems that are

interchangeable and configurable to suit many refrigeration applications. The subsystems are designed to minimize freight cost associated with the refrigerated storage system 10.

[0033] The refrigerated storage system 10 includes a refrigerated enclosure 12 bounding a refrigerated area 14 and a refrigeration unit configured to cool the refrigeration area. It will be understood that the refrigerated enclosure 12 can partially or completely enclose the refrigerated area 14. The refrigerated enclosure 12 has shelves for organizing and holding refrigerated merchandise and transparent doors 18 for displaying the merchandise in a retail setting. In other embodiments, the

refrigerated enclosure can be a storage case with opaque, insulated doors (not shown) or no doors (not shown). In the illustrated embodiment, the modular refrigerated enclosure 12 comprises a display case including a plurality of refrigerated zones 20 in a side-by-side arrangement. Each refrigerated zone 20 has an insulated wall 22 which bounds the top, rear, and bottom of a respective merchandise region 24. A door 18 bounds the front of each merchandise region 24. Though each refrigerated zone 20 has a single door 18 in the illustrated embodiment, it will be understood that a refrigerated zone can include more than one door without departing from the scope of the invention. Insulating side walls (not shown) can be attached to the sides of the display case 12 to bound the sides of the refrigerated area 14. In the illustrated embodiment, the interior sides of each merchandise region 24 are not separated from one another. However, interior side walls can be used to separate the interior sides of each merchandise region without departing from the scope of the invention. Other configurations of the refrigerated zones are possible within the scope of the invention. Moreover, the refrigerated enclosure can be other than a display case. Indeed, the refrigerated enclosure need not be of the type associated with supermarket or even food storage within the scope of the present invention.

[0034] As will be understood by a person having ordinary skill in the art, a conventional refrigeration unit comprises a compressor, a condenser, an expansion device, an evaporator, and interconnecting piping. The function of the compressor is to receive low pressure and temperature refrigerant vapor from the evaporator and compress it into a high pressure and temperature vapor. The high pressure vapor is then converted to a liquid phase in the condenser. The condenser performs this function by removing heat from the vapor and rejecting the heat to the outside environment. The liquid, which remains at a high pressure, passes through the expansion device and becomes a low pressure two phase (liquid and vapor) mixture. The refrigerant mixture returns to its vapor phase in the evaporator by absorbing heat from the air being cooled. A fan connected to the evaporator circulates the cooled air inside the refrigerated area to produce a desired temperature detected by a sensor in the interior space.

[0035] In the illustrated embodiment, a mechanical room 26 located remote from the refrigerated zone 20 houses the compressor(s) for the refrigerated storage system. Typically, the condenser(s) will be located on the roof. It will be understood that the compressor and condenser may be located in other places within the scope of the invention. As shown in Fig. 2, a cooling system 30 comprising an expansion device (not shown), an evaporator 32 (broadly, a cooling device) and blower 34 (broadly, an air moving device) is mounted above each refrigerated zone 20 (remote from the mechanical room 26) outside of the respective merchandise region 24. More specifically, an expansion valve, evaporator 32, and blower 34 are mounted on top of the respective refrigerated zone 20 and housed by a selectively removable access cover 40 that, when secured to the display case 12 above the refrigerated zone, bounds a cooling system chamber 42 for the respective refrigerated zone. Piping separately connects the high pressure liquid refrigerant from the condenser to each expansion valve and likewise connects the low pressure refrigerant from each evaporator 32 to the compressor. Though the illustrated embodiment uses a separate evaporator 32 and blower 34 for each of the refrigerated zones 20, it will be understood that a cooling system can be used to cool more than one refrigerated zone in a refrigerated enclosure without departing from the scope of the invention. [0036] For each refrigerated zone 20, the blower 34 draws in return air from the merchandise region 24 through a return air flue 44, which has an outlet port 46 adjacent the rear of the cooling system chamber 42. The blower 34 blows the return air over the evaporator 32 to cool it. Referring to Figs. 2 and 4, the cooled air flows through a discharge air flue 48, which has an inlet port 50 adjacent the front of the cooling system chamber, and into the merchandise region 24 to cool the zone. Though the inlet port 50 for the discharge air flue 48 is located adjacent the front of the refrigerated zone 20 in the illustrated embodiment, it is contemplated that it can be located elsewhere without departing from the scope of the invention. Preferably, the inlet port of the discharge air flue and the outlet port of the return air flue are positioned adjacent opposite ends of the cooling system chamber. Preferably, the blower 34 and

evaporator 32 are positioned relative the outlet port 46 of the return air flue 44 and the inlet port 50 of the discharge air flue 48 to blow return air from the return air flue over the evaporator before being discharged through the discharge air flue. In the illustrated embodiment, the blower 34 is positioned adjacent the outlet port 46 of the return air flue 44 and the evaporator 32 is positioned adjacent the inlet port 50 of the discharge air flue 48.

[0037] Referring to Figs. 3 and 4, the access cover 40 is shaped to condition the flow profile of the cooled air as it enters the merchandise region 24. In addition, an air straightener 52 (broadly, a gas flow conditioner) is positioned within the discharge air flue 48 to condition the flow profile of the cooled air as it enters the merchandise region 24. The front, rear, and top walls 54, 56, 58 of the access cover 40 bound the front, rear, and top sides of the cooling system chamber 42. The top wall 58 of the access cover 40 is oriented substantially parallel to the top portion of the insulated wall 22. Likewise, the rear wall 56 of the access cover 40 is oriented substantially parallel to the rear portion of the insulated wall 22. The rear and top walls 56, 58 are oriented substantially perpendicular to one another. The front wall 54 of the access cover 40 has an inboard surface 60 and an outboard surface 62 and a thickness between the inboard and outboard surfaces. The thickness of the front wall 54 narrows as the wall extends from the top end (adjacent the top wall 58) to the bottom end (adjacent the insulating wall 22). The outboard surface 62 of the front wall 54 is substantially planar and oriented at an obtuse angle relative the top wall 58. [0038] The inboard surface 60 of the front wall 54 (broadly, a cooled air directing surface) is contoured and angled relative the top wall to direct cooled air into the inlet port 50 of the discharge air flue 48. In the illustrated embodiment, the inboard surface 60 includes five generally planar facets 60A-60E that direct the flow of cooled air into the discharge air flue 48. Although the inboard surface 60 of the front wall 54 includes five facets 60A-60E, it will be understood that other numbers of facets can be used without departing from the scope of the invention. The first facet 60A is positioned adjacent the top wall 58 and oriented at a first obtuse angle a with respect thereto. Preferably, the angle a is between about 100° and about 120°. The second facet 60B extends outward with respect to the first facet 60A and is oriented at a second obtuse angle Θ with respect to the third facet 60C. In one or more preferred embodiments, the second obtuse angle Θ is between about 130° and about 150°. The fourth facet 60D extends outward from the third facet 60C and forms a third obtuse angle Ψ with respect to the fifth facet 60E. Preferably, the third obtuse angle Ψ is between about 1 10° and about 130°. The first, second, and third obtuse angles α, θ, Ψ create three concave formations on the inboard surface 60 of the front wall 54. The concave formations each function to direct the flow of cooled air into the inlet port 50 of the discharge air flue 48. The blower 34 blows air through the cooling system chamber 42 in a generally horizontal direction (e.g., substantially parallel to the top wall 58). The facets 60A-60E are oriented to deflect the horizontally moving cooled air downward toward the discharge air flue 48 when the cooled air strikes the inboard surface 60 of the front wall 54 of the cover 40.

[0039] Referring to Fig. 7, the inboard surface 60 of the front wall 54 preferably conditions the air flow to have a mixed flow profile at the inlet port to the flow

straightener 52. The blower 34 blows air through the cooling system chamber 42 in a generally horizontal direction. The air initially travels away from the blower 34 at a high velocity. When the moving air contacts the inboard surface 60 of the front wall 54 it is deflected downward toward the inlet port of the flow straightener 52. The velocity of the deflected air decreases and continues to decrease as it travels further downward toward the inlet port of the flow straightener 52. The slower moving, downwardly traveling air adjacent the inboard surface 60 of the front wall 54 mixes with fast moving, horizontally traveling air from the blower 34. The amount of mixing increases from adjacent the top end of the front wall 54 toward the bottom end of the top wall so that the air is thoroughly mixed when it enters the flow straightener. In the illustrated embodiment, the angles α, θ, Ψ are all different so that the moving air behaves differently at each concavity formed by the facets 60A-60E. This is also thought to improve the mixed flow profile at the inlet port of the flow straightener 52.

[0040] Referring to Fig. 16, in certain embodiments, an air curtain 61 is positioned within the cooling system chamber 42 to define first and second air flues 61 A, 61 B for delivering blown air to the flow straightener 52. The air curtain 61 includes a top segment that extends generally parallel to the top wall 58 of the access cover 40 and a front segment that extends generally parallel to the front wall 60 of the access cover. Like the front wall 60 of the access cover 40, the front segment of the air curtain 61 is multifaceted to promote mixing of the blown air before it enters the straightener 52. The first air flue 61 A is positioned between the air curtain 61 and the top insulated wall 22, below the top segment of the air curtain and to the rear of the front segment of the air curtain. The evaporator 32 is positioned in the first air flue 61 A, between the air curtain 61 and the top insulating wall 22. The second air flue 61 B is positioned between the air curtain 61 and the access cover 40, above the top segment of the air curtain and in front of the front segment of the air curtain. In use, the blower 34 blows the return air forward through the cooling system chamber 42. Some of the blown air enters the first air flue 61 A and passes over the evaporator 32 before entering the flow straightener 52, and the rest of the blown air enters the second air flue 61 B. The portion of the blown air that travels through the second air flue 52 does not pass over the evaporator 32 before entering the flow straightener 52. The warmer air from the air flue 61 A provides an air curtain barrier adjacent the front of the display case 12 to ingress of the much warmer air outside of the display case.

[0041] Referring to Fig. 8, another suitable access cover for covering the cooling system chamber 142 is generally indicated at 140. Like the access cover 40, the access cover 140 is shaped to condition the flow profile of cooled air as it enters the merchandise region 24. The access cover 140 has a front wall 154, a rear wall 156, and a top wall 158 that respectively bound the front, rear, and top sides of the cooling system chamber 42 in use. The top wall 158 includes a rear portion 158A that extends generally horizontally from the rear wall 156. An inner portion 158B of the top wall 158 extends generally downward along a vertical axis from a front end of the rear portion 158A. In the illustrated embodiment, the inner portion 158B is oriented generally perpendicular to the rear portion 158A. A front end portion 158C angles upward from a bottom end of the inner portion 158B toward a front end of the top wall 158. Thus, the top wall 158 forms a depression that provides space for a handle 159 to be mounted on front portion 158C the top wall. The handle 159 extends up from the front portion 158C without substantially increasing the overall height of the access cover 140. The handle 159 can be used for installing and removing the access cover 140.

[0042] Air is configured to be blown through cooling system chamber 142 from adjacent the rear wall 156 toward the front wall. As the blown air strikes the front wall 154, the front wall 154 is configured to cause mixing before the air enters the air straightener 52. As with the access cover 40, the front wall 154 of the access cover 140 defines a multifaceted inboard surface 160. The surface 160 includes a first facet 160A that extends from adjacent the front end portion 158C of the top wall 158 to a bottom end portion spaced apart from the top wall 158. The first facet 160A is oriented at an angle with respect to the front end portion 158C of the top wall 158. In one or more embodiments, the angle is from about 80° to about 120°. The blower 34 can suitably be configured to blow air through the cavity 142 along a flow path oriented generally perpendicular to the first facet 160A. A second facet 160B extends downward along a vertical axis from the first facet 160A at an obtuse angle βι with respect to the first facet. Suitably, the angle can be from about 140° to about 180°. The first and second facets 160A, 160B, therefore, define a first concave formation that promotes mixing when the cooled air strikes the inboard surface 160 of the front wall. A third facet 160C extends further downward and outward from the second facet 160B at an obtuse angle ει with respect to the second facet. In one or more embodiments the angle ει is from about 130° to about 170°. A fourth facet 160D extends from the third facet 160C downward and outward (though at less of an outwardly extending angle than the third facet) at an obtuse angle with respect to third facet. The angle can be from about 140° to about 180°. Thus, the third and fourth facets 160C, 160D define a second concave formation with a different orientation than the first concave formation that causes further mixing of the blown air as it strikes the inboard surface 160 of the front wall 154. A fifth facet 160E extends downward and outward from the fourth facet 160D at an acute angle λ with respect to the fourth facet.

[0043] In general, whether the first access cover 40 or second access cover 140 is used, the blown air enters the straightener 52 with a mixed profile. Since the air enters the flow straightener 52 with a mixed flow profile, the flow straightener can be configured to consistently produce a desired flow profile at its outlet port. As shown in Figs. 5A-5C, the inboard surface 60 of the front wall 54 of the access cover 40 and the air straightener 52 preferably condition the flow of cooled air into the merchandise region 24 to have a ramp (Fig. 5A), plug (Fig. 5B), or mixed (Fig. 5C) flow profile at the outlet of the discharge flue 48. A ramp flow profile gradually transitions from relatively high air flow velocity at the inboard end of the discharge air flue 48 to relatively low air flow velocity at the outboard end. It is particularly contemplated that a flow straightener configured to produce a ramp flow profile is used to generate a horizontal air curtain in, for example, an open top refrigerated case to inhibit infiltration of outside air into the interior of the case. A plug flow profile has substantially constant flow velocity between the inboard and outboard ends of the discharge air flue 48. It is particularly

contemplated that a flow straightener configured to produce a plug air profile is used with a refrigerated case having vertically oriented doors to inhibit air infiltration into the interior of the case when one or more doors are open. A mixed air flow profile has characteristics of both the ramp and plug flow profiles. It is particularly contemplated that a flow straightener configured to produce a mixed air profile is used to generate a vertical air curtain in, for example, an open front refrigerated case to inhibit infiltration of outside air into the interior of the case. It will be understood that the ramp, plug, and mixed flow profiles can be used with other than the above-explained embodiments of refrigerated cases without departing from the scope of the invention.

[0044] As shown in Figs 6A and 6B, the access covers 40 for the refrigerated zones 20 are configured to be joined together at their sides to form a substantially continuous cover panel. Adjacent sides of the access covers 40 include interlocking formations that can be selectively mated to join the access covers at their sides. For example, in one embodiment shown in Fig. 6A, the sides of adjacent access covers 40 form a half-lap scarf joint. In another example shown in Fig. 6B, the sides of adjacent access covers 40 form a tongue-and-groove joint. Other types of interlocking formations can also be used without departing from the scope of the invention. The side-by-side interlocking engagement of the access covers 40 enables individual removable covers to be selectively removed and secured to a respective one of the refrigerated zones 20 to enable maintenance access to an individual cooling system 40. [0045] With the illustrated refrigeration system 10, each refrigeration refrigerated zone 20 in the display case 12 has its own cooling system 30, which is located adjacent the merchandise region 24 but is outside of the merchandise region within its own cooling system chamber 42. The proximity between the cooling system 30 and its merchandise region 24 enables cool air to be delivered to the merchandise region with high efficiency, and the separation between the cooling system and the merchandise region permits maintenance work to be performed on the cooling system without requiring merchandise contained within the merchandise region to be moved. Access covers 40 house the cooling systems 30 within the respective cooling system chambers 42 and are each selectively removable to permit access to the cooling systems for maintenance and repair. Each access cover 40 is shaped to efficiently deliver cool air through the discharge air flue 48 and into the merchandise region. In combination with the air straightener 52 in the discharge air flue 48, the contoured shape of the cooled air directing surface 60 of the access cover 40 delivers cooled air into the merchandise region 24 with a desired flow profile. Each one of the access covers 40 can be individually and selectively removable to allow for maintenance of each of the cooling systems 30 separately. In addition, the access covers 40 are joinable along their sides to securely enclose the cooling systems 30 atop the refrigerated zones 20 in a visually appealing way.

[0046] Referring to Figs. 9-15, a modular refrigeration system with

interchangeable and adaptable subsystems is generally indicated at 1 10 (Figs. 14 and 15). The illustrated modular refrigeration system 1 10 is a merchandising display case with transparent doors. It will be understood, however, that other types of modular refrigeration systems can also be used without departing from the scope of the invention. In a preferred embodiment, an insulation subsystem 1 1 1 , storage subsystem 1 13, viewing subsystem 1 15, and refrigeration subsystem 130 are assembled together to form the modular refrigeration system 1 10.

[0047] Referring to Fig. 9, the insulation subsystem 1 1 1 includes a plurality of insulating panels configured to be joined together to form a refrigerated enclosure 1 12 that at least partially bounds a refrigerated area 1 14. For example, the insulation subsystem 1 1 1 can include one or more rear insulating panels 121 , one or more side insulating panels (not shown), one or more top insulating panels 123, one or more bottom insulating panels (not shown), and one or more front insulating panels 125. In a preferred embodiment, each insulating panel is a substantially planar body of material so that the insulating panels can be laid flat against one another after they have been formed for shipping the panels together in a pre-assembly, flat-packed package. It will be understood that package can mean any structure for retaining the panels in the flat- packed arrangement (e.g., a box, a bundling strap, etc.). The insulating panels 121 , 123, 125, can have interlocking features to aid in joining the panels together to assemble the insulation subsystem 1 1 1 at or near the deployment site for the modular refrigeration system 1 10.

[0048] In a preferred embodiment, the insulating panels 121 , 123, 125 are molded foam pieces. As shown in Fig. 17, rigid cam lock nuts 201 are molded or otherwise inserted into the foam pieces to receive mating cam lock screws 203 for joining the foam pieces together. Referring again to Fig. 9, in one or more

embodiments, the insulating panels 121 , 123, 125 define one continuous rear wall of refrigerated enclosure, one continuous top wall of the enclosure, opposite continuous side walls of the enclosure (not shown), and spaced apart top and bottom portions of a front wall of the enclosure. In such an embodiment, the refrigeration system 1 10 is preferably supported on a surface S (Fig. 15) that provides insulation at the bottom of the enclosure 1 12. Slots 127, 129 are preferably formed in one or more insulating panels 123 defining the top wall of the enclosure for connecting the refrigeration subsystem to the refrigerated area 1 14 bounded by the refrigerated enclosure 1 12. For example, a rear slot 127 in the top wall defines an outlet port for a return air duct 144 (Fig. 15) that delivers return air to a cooling system 130 mounted on top of the refrigeration system 1 10. A front slot 129 in the top wall at least partially bounds a discharge air duct that delivers cooled air to the refrigerated area 1 14. In one or more embodiments, an upper front insulating panel 125 also partially bounds the discharge air duct.

[0049] Referring to Fig. 10, the storage subsystem 1 13 includes one or more support brackets 131 configured to be attached to the insulating panels 121 , 123, 125 for supporting the insulating panels in position to form the refrigerated enclosure 1 12. The support brackets 131 comprise one or more support bracket members. Each of the support bracket members is preferably a substantially planar body of material so that the bracket members can be laid flat against one another after they have been formed for shipping in a pre-assembly, flat-packed state. In one or more embodiments, each support bracket 131 comprises an upright bracket member 133, top bracket member 135, and bottom bracket member 137, which are selectively joinable to form a C-shaped support bracket. The upright bracket member 133 is secured to an insulating panel 121 forming the rear wall of the refrigerated enclosure 1 12 (e.g., using machine screws configured to mate with nuts inserted into the insulating panel) and extends between the top wall and lower support surface S. The top bracket member 135 is secured to an insulating panel 123 forming the top wall of the refrigerated enclosure 1 12 and extends between the rear and front walls. The bottom bracket member 137 is secured to the lower support surface S (e.g., using anchors, etc.) and also extends between the rear and front walls. The storage subsystem 1 13 can include a plurality of support brackets spaced apart along the width of the refrigerated enclosure, as shown in Fig. 10.

[0050] Referring to Fig. 1 1 , one or more interior panels 141 are configured for attachment to the inner sides of the support brackets 131 to bound an interior space of the refrigerated area 1 14. Each interior panel 141 is preferably a substantially planar body of material so that the interior panels can be laid flat against one another after they have been formed for shipping together in a pre-assembly, flat-packed package. The interior panels 141 can, for example, include one or more rear panels, one or more top panels (not shown), and one or more bottom panels spaced apart from respective insulating panels 121 , 123, 125 by the support brackets 131 . Preferably, the interior panels 141 , support brackets 131 , and insulating panels 121 , 123, 125 bound air handling ducts 144 of the refrigerated system, as shown in Fig. 15. More specifically, return air flows into an inlet port defined by the front end of a bottom interior panel 141 and a rear side of a lower front insulating panel 125, through a lower leg of a return air duct 144 partially bounded by a lower interior panel and a support surface S, through an upright leg of the return air duct partially bounded by a rear interior panel 141 and rear insulating panel 121 , and out the discharge port 127. The air handling ducts 144 also function as conduits through which piping and electrical cables for the refrigeration system are run. For example, before installing the interior panels, one or more upright drain pipes 143 (Fig. 10) are installed in the upright leg of the return air duct 144 adjacent the rear insulating panels 121 . Electrical wiring as well as any other connection (e.g., for refrigerant, drains etc.) may be provided with quick connect features to permit rapid assembly. [0051] As shown in Fig. 12, the storage subsystem 1 13 also includes shelving 151 configured for mounting on the upright bracket members 133 of the support brackets 131 . Different types of shelving can be mounted on the support brackets 131 to suit the purpose of the refrigeration system 1 10.

[0052] Referring to Fig. 13, in the illustrated embodiment the visualization subsystem 1 15 includes transparent glass doors 161 that allow viewing of the merchandise. However, with other types of refrigeration systems, the visualization system may not include doors. The visualization subsystem 1 15 suitably includes one or more light fixtures (e.g., LED light fixtures, not shown) mountable within the refrigerated enclosure 1 12 to illuminate the refrigerated enclosure. The insulation and storage subsystems 1 1 1 , 1 13 include electrical connectors for connecting the light fixtures to a source of electricity. Likewise, the insulation and storage subsystems 1 1 1 , 1 13 include mounts for securing the lighting fixtures to the refrigerated enclosure.

Different types of lighting fixtures can be secured to the mounts and connected to the electrical connectors.

[0053] Referring to Figs. 14 and 15, as discussed above in reference to the refrigeration system 10, the refrigeration subsystem 130 preferably includes a cooling system mounted on the top of the refrigerated enclosure 1 12 and the access cover 140 (discussed above in reference to Fig. 8) removably attached to the refrigerated enclosure for enclosing the cooling system. It will be understood that the cooling system 130 is preferably configured for operative connection with the air handling ducts 144 defined by the insulation and storage subsystems 1 1 1 , 1 13. In addition to the cooling system, the refrigeration subsystem 130 can include refrigeration equipment located remotely from the refrigerated enclosure (not shown) as discussed above.

[0054] The modular refrigeration system 1 10 can be manufactured and shipped to location at a minimal cost as compared with prior art refrigeration systems. Since components of the insulation subsystem 1 1 1 and storage subsystem 1 13 are able to lie flat against one another during shipping, overall transportation volume is reduced. In addition, the modular refrigeration system 1 10 enables an end user to select from subsystems that optimally suit the desired purpose. Any of an array of insulation subsystems, storage subsystems, visualization subsystems, and refrigeration subsystems can be mixed and matched to assemble the optimum refrigeration system for a particular purpose. Suitable fixturing can be provided to facilitate assembly of a finished case or refrigerated enclosure from the shipped components. In at least some embodiments, the fully assembled refrigerated enclosures have an open bottom. The bottom wall of the refrigerated enclosure can be formed by a floor of an establishment in which the refrigerated enclosure is installed, at such time as it is installed at the establishment.

[0055] Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.

[0056] When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles "a", "an", "the" and "said" are intended to mean that there are one or more of the elements. The terms "comprising", "including" and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0057] In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

[0058] As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Claims

WHAT IS CLAIMED IS:

1 . A refrigeration system for storing perishable items at a cooled

temperature comprising:

an enclosure comprising an insulated wall at least partially bounding a refrigerated area for receiving the perishable items;

a cooling system for cooling air in the refrigerated area, the cooling system being mounted on the enclosure; and

an access cover selectively securable to the enclosure for housing the cooling system in a cooling system chamber partially bounded by the access cover, the access cover being selectively removable to permit access to the cooling system without entering the refrigerated area.

2. A refrigeration system as set forth in claim 1 wherein the cooling system is mounted on an upper portion of the insulated wall above the refrigerated area.

3. A refrigeration system as set forth in claim 1 wherein the cooling system is configured to deliver cooled air to the refrigerated area through a discharge air flue, the access cover being configured and arranged to direct the cooled air into an inlet port of the discharge air flue.

4. A refrigeration system as set forth in claim 3 wherein the access cover comprises a top wall and opposite end walls, one of the end walls being located adjacent the inlet port of the discharge air flue and being arranged to deflect the cooled air toward the inlet port of the discharge air flue.

5. A refrigeration system as set forth in claim 4 wherein said one of the end walls comprises an inboard surface, at least a portion of the inboard surface being oriented at an obtuse angle relative the top wall.

6. A refrigeration system as set forth in claim 5 wherein the inboard surface comprises a plurality of generally planar facets, adjacent ones of the facets being oriented at an angle with respect to one another.

7. A refrigeration system as set forth in claim 6 wherein alternating adjacent pairs of the facets form concave formations arranged to direct the cooled air toward the inlet port of the discharge air flue.

8. A refrigeration system as set forth in claim 4 wherein the discharge air flue comprises a flow conditioner configured to condition the flow of air into the refrigerated area.

9. A refrigeration system as set forth in claim 8 wherein said one of the end walls and the flow conditioner are configured to condition the flow of cooled air from the outlet of the discharge air flue to have one of a ramp flow profile, a plug flow profile, and a mixed flow profile.

10. A refrigeration system as set forth in claim 1 wherein the enclosure comprises a plurality of refrigerated zones, each refrigerated zone comprising an insulated wall at least partially bounding a refrigerated zone.

1 1 . A refrigeration system as set forth in claim 10 wherein the refrigeration system comprises a cooling system for each of the refrigerated zones, each cooling system being mounted on the insulated wall of the respective refrigerated zone.

12. A refrigeration system as set forth in claim 1 1 wherein the refrigeration system comprises an access cover for each refrigerated zone, each access cover being selectively securable to the respective refrigerated zone for housing the respective cooling system in a cooling system chamber partially bounded by the access cover, each access cover being selectively removable.

13. A refrigeration system as set forth in claim 12 wherein adjacent sides of the access covers comprise mating interlocking formations for joining the access covers along the adjacent sides.

14. A refrigeration system as set forth in claim 13 wherein the interlocking formations comprise one of a half-lap scarf joint and a tongue-and-groove joint.

15. A refrigeration system as set forth in claim 1 wherein the enclosure includes a discharge air flue and the cooling system comprises an air moving device configured to draw return air from the refrigerated area into the cooling system chamber, blow the return air over a cooling device to cool the air, and deliver the cooled air into the refrigerated area through the discharge air flue.

16. A refrigeration system as set forth in claim 15 wherein the air moving device is configured to blow the return air over the cooling device in a horizontal direction.

17. A refrigeration system as set forth in claim 16 wherein the enclosure includes a return air flue comprising an outlet port located adjacent a rear end of the refrigeration system and the discharge air flue comprises an inlet port located adjacent a front end of the refrigeration system.

18. A refrigeration system as set forth in claim 17 wherein the air moving device is located adjacent the outlet port of the return air flue and the cooling device is located adjacent the inlet port of the discharge air flue.

19. A refrigeration system as set forth in claim 1 wherein the cooling system is operatively connected to at least one compressor positioned within a mechanical room located remote from the enclosure.

20. An access cover for housing a cooling system of a refrigeration system, the access cover comprising:

a top wall and opposite end walls configured to be secured to a refrigerated enclosure to partially bound a cooling system chamber, the cooling system being located within the cooling system chamber, the access cover being selectively removable from the refrigerated enclosure to permit access to the cooling system in the cooling system chamber.

A refrigerated case for use in a modular refrigeration system for cooling a refrigerated area, the refrigerated case comprising:

an insulated wall at least partially bounding a refrigerated zone of the

refrigerated area;

a cooling system for cooling the refrigerated zone, the cooling system being mounted on the insulated wall; and

an access cover selectively securable to the insulated wall to house the cooling system in a cooling system chamber, the access cover being selectively removable to permit access to the cooling system in the cooling system chamber.

21 . A refrigerated case as set forth in claim 21 further comprising an air curtain positioned in the cooling system chamber to define first and second flow paths for directing blown air toward the refrigerated zone.

22. A method of manufacturing a refrigeration system comprising:

removing insulating panels from a package in which the insulating panels are laid flat against one another; and

joining the insulating panels together to form at least one insulating wall of a refrigerated enclosure of the refrigeration system.

23. A method of manufacturing a refrigeration system as set forth in claim 22 further comprising:

removing support brackets from a package in which the support brackets are laid flat against one another; and

attaching the support brackets to the insulating panels.

24. A method of manufacturing a refrigeration system as set forth in claim 23 further comprising;

removing interior panels from a package in which at least some of the interior panels are laid flat against one another; and

attaching at least some of the interior panels to at least one of the support brackets to from an interior wall of the refrigerated enclosure, the interior wall being spaced apart from the at least one insulating wall by said at least one of the support brackets and the interior wall and insulating wall at least partially bounding an air handling duct of the refrigeration system.

25. A refrigeration system comprising an insulation subsystem comprising a plurality of insulating panels joined together with mated cam nuts and cam screws.

26. A refrigeration system as set forth in claim 25 wherein each of the insulated panels comprises a molded foam body.

27. A refrigeration system as set forth in claim 26 wherein the cam nuts are molded into the molded foam bodies.

28. A method of manufacturing a refrigeration system comprising:

separately forming components of the refrigeration system at a first location; transporting the separately formed components in an unassembled configuration to a second location remote from the first location; and

assembling the separately formed components together at the second location to form at least a portion of the refrigerated system at the second location.

29. A method of manufacturing a refrigeration system as set forth in claim 28 wherein the components are substantially planar components.

30. A method of manufacturing a refrigeration system as set forth in claim 29 further comprising, before said transporting, packaging the components one on top of another so that broad sides of at least some adjacent components overlay one another and are oriented parallel to one another.

31 . A method of manufacturing a refrigeration system as set forth in claim 28 wherein the components comprise insulating panels and said forming step comprises molding the insulating panels from foam.

32. A method of manufacturing a refrigeration system as set forth in claim 28 wherein said forming step further comprising molding at least one cam lock nut into one of said insulating panels.

33. A refrigerated display case comprising walls forming an insulated enclosure and an open bottom whereby the floor of the establishment in which the display case may be located forms a bottom of the display case at such time as the display case is installed at the establishment.

34. A refrigerated case for use in a modular refrigeration system for cooling a refrigerated area, the refrigerated case comprising:

an insulated wall at least partially bounding a refrigerated zone of the

refrigerated area; a cooling system for cooling the refrigerated zone, the cooling system being mounted on the insulated wall;

an access cover mountable on the insulated wall to house the cooling system in a cooling system chamber; and

an air curtain positioned in the cooling system chamber to define first and second flow paths in the cooling system chamber.