CLIMATE CONTROL DOOR SYSTEM AND METHODS

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority to and incorporates by reference the entire contents of provisional patent application Ser. No. 63/646,253 entitled “Climate Control Door System and Methods,” filed 13 May 2024.

BACKGROUND

Refrigerated enclosures (e.g., reefers, coolers, walk-in freezers, storage containers, etc.) have long been used to cool goods (e.g., food, meat, perishable item, etc.). Often, refrigerated enclosures have a built-in climate control unit (e.g., air conditioner, heat pump, etc.). Thus, heat may be removed from the interior of the enclosure, cooling the items within the enclosure.

While traditional refrigerated enclosures provide many benefits, they are also subject to various drawbacks. In traditional refrigerated enclosures, built-in climate control units are often difficult to access for maintenance. Further, in traditional refrigerated enclosures, if the climate control unit malfunctions, the entire enclosure is taken out of service and the goods within the enclosure must be quickly moved to another functioning refrigerated enclosure. Accordingly, more sophisticated and versatile refrigerated enclosures would be useful.

SUMMARY

The present invention is generally directed to a climate-controlled enclosure, and more particularly, a climate control door system for an enclosure. The climate control door system can include a door assembly and a door-mounted climate control unit, or air conditioner unit. The enclosure can include one or more walls, including sidewalls, a floor, and/or a ceiling that collectively define an enclosed interior space. The enclosure can include a port defined through one of the walls. A door can be pivotally mounted to the enclosure and configured to pivot between a closed position in which the port is covered and an open position in which the port is uncovered. A climate control unit, or air conditioner unit, can be mounted to the door such that pivoting the door into the open position extracts the climate control unit from the enclosure and pivoting the door into the closed position inserts the climate control unit into the enclosure.

Some embodiments provide a climate control door assembly including a door panel and a climate control unit. The door panel is configured to connect to a frame panel. The climate control unit is mounted to the door panel.

In some embodiments, the climate control unit includes an interior portion and an exterior portion.

In some embodiments, the interior portion is operably connected to the exterior portion via an opening defined in the door panel.

In some embodiments, the interior portion is operably connected to the exterior portion via a conduit.

In some embodiments, the interior portion includes an evaporator and the exterior portion includes a condenser.

In some embodiments, the interior portion is a cooling portion of the climate control unit and the exterior portion is a heating portion of the climate control unit.

In some embodiments, the cooling portion is on a first side of the door panel and the heating portion is on a second side of the door panel.

In some embodiments, the climate control unit is at least partially supported by a bracket mounted to the door panel.

In some embodiments, the bracket extends beyond a lower edge of the door panel.

In some embodiments, an elastomeric seal is mounted to the door panel.

In some embodiments, a locking latch is mounted in the door panel.

In some embodiments, the locking latch is operable via a pull loop extending from an interior side of the door panel.

In some embodiments, the locking latch is operable via a handle mounted to an exterior side of the door panel.

In some embodiments, the door panel is configured to pivotally connect to the frame panel.

In some embodiments, the door panel is configured to connect to the frame panel via hinges.

In some embodiments, the hinges are separable.

Some embodiments provide an enclosure panel including a frame and a climate control door assembly. The frame defines an opening. The climate control door assembly is connected to the frame to close the opening. The climate control door assembly includes a door panel and a climate control unit mounted to the door panel.

In some embodiments, the climate control door assembly is removably connected to the frame.

In some embodiments, the climate control unit includes an interior portion and an exterior portion.

In some embodiments, the interior portion is operably connected to the exterior portion via an opening defined in the door panel.

In some embodiments, the enclosure panel, further includes a cage interiorly mounted to the frame and blocking the opening.

Some embodiments provide a method for maintaining a climate control unit that includes opening a climate control door assembly from a closed configuration to an open configuration relative to a frame, the climate control door assembly including a climate control unit mounted to a door panel; performing at least one of an inspection, a repair, and a cleaning protocol on the climate control unit; and closing the climate control door assembly from the open configuration to the closed configuration relative to the frame.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of embodiments of the disclosure:

FIG. 1 is an isometric view of an enclosure in a closed configuration, according to an embodiment;

FIG. 2 is an isometric view of the enclosure of FIG. 1 in an open configuration;

FIG. 3 is an isometric view of the enclosure in the closed configuration of FIG. 1 with a climate control unit and a cover panel removed for clarity;

FIG. 4 is a side isometric view of a climate control door assembly of the enclosure of FIG. 1;

FIG. 5 is a rear isometric view of the climate control door assembly of FIG. 4;

FIG. 6 is a flow diagram depicting a method to perform maintenance on the climate control unit of FIG. 1 via the climate control door assembly of FIG. 4, according to the principles of this disclosure;

FIG. 7 is a perspective view of an enclosure having a climate control door system, illustrating the door system in a closed configuration, according to an embodiment; and

FIG. 8 is a perspective view of the enclosure of FIG. 7, illustrating the climate control door system in an open configuration.

DETAILED DESCRIPTION

The following discussion is presented to enable a person skilled in the art to make and use embodiments of the disclosure. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.

Before any embodiments of the invention are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the attached drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. For example, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

As used herein, unless otherwise specified or limited, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, unless otherwise specified or limited, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

As used herein, unless otherwise specified or limited, “at least one of A, B, and C,” and similar other phrases, are meant to indicate A, or B, or C, or any combination of A, B, and/or C. As such, this phrase, and similar other phrases can include single or multiple instances of A, B, and/or C, and, in the case that any of A, B, and/or C indicates a category of elements, single or multiple instances of any of the elements of the categories A, B, and/or C.

As explained above, it would be useful to provide more sophisticated and versatile climate-controlled or refrigerated enclosures that facilitate maintenance of climate control units, help maintain contents within the enclosure at a desired temperature, humidity and other conditions, and/or help prevent refrigerated goods from spoiling should the climate control unit malfunction.

Referring to the several figures, the present invention is directed to an enclosure 100 that is configured with a removable climate control unit 136 (e.g., air conditioner unit) for selectively controlling the climate of the interior of the enclosure 100. As described in greater detail herein, the climate control unit 136 may be mounted in a door assembly 122 to facilitate removal, adjustment, modification and/or maintenance to the climate control unit 136 or the enclosure 100. The door assembly 122 is mounted on an exterior wall of the enclosure 100 and configured for pivotable rotation within an opening or port 120 defined through the exterior wall of the enclosure. The climate control unit 136 is mounted to the door assembly 122, which is configured to pivot between a closed position (sec. FIG. 7) in which the opening 120 is covered by the door assembly 122 and an open position (see FIG. 8) in which the opening 120 is uncovered. Pivoting the door assembly 122 into the open position extracts the climate control unit 136 from the enclosure 100 and pivoting the door assembly 122 into the closed position inserts the climate control unit 136 into the enclosure 100. The structural components, operation and configurations of the disclosure are described in additional detail below.

The enclosure 100 may also be configured for any suitable application. In some embodiments, the enclosure 100 may be a walk-in refrigeration unit, a storage container or any other desired enclosure with one or more defined boundary walls for defining an enclosure space. It will also be appreciated that the enclosure 100 may have any suitable size and configuration depending on the desired application.

FIG. 1 illustrates an enclosure 100 according to an embodiment. In some embodiments, the enclosure 100 includes a bottom panel 102 opposite a top panel 104 and connected to a first side panel 106 and a front panel 108. The first side panel 106 defines a primary access opening 110. A primary access door 112 is pivotably connected to the first side panel 106 to selectively and securely close the primary access opening 110. The primary access opening 110 provides access for a user to enter an interior space 114 defined by the enclosure 100. The user may thus, for example, deposit and remove goods from the enclosure 100.

Remaining with FIG. 1, the front panel 108 defines a climate control opening 120. A climate control door assembly 122 is pivotably connected to the front panel 108 to selectively, sealably, and securely close the climate control opening 120. More specifically, a plurality of hinges 124 swingably connect a door panel 126 to the front panel 108. The hinges 124 are separable, thus the climate control door assembly 122 is removable from the front panel 108. Further, a latch assembly 128 mounted in the door panel 126 selectively locks the door panel 126 to the front panel 108 in a closed configuration 130. At least one bracket 132 is mounted to and extends from the door panel 126 to support an exterior portion 134 of a climate control unit 136. Additionally, a cover panel 138 is mounted to the door panel 126 between the brackets 132. Elastomeric seals 140 are also mounted to the door panel 126 to sealably engage the front panel 108. In some embodiments, the brackets 132 extend beyond a lower edge 142 of the door panel 126.

Looking still at FIG. 1, it should be understood and appreciated that by removing the climate control door assembly 122 from the front panel 108, maintenance and/or cleaning of the climate control unit 136 may be performed more easily in a workshop rather than in situ at the enclosure 100. Further, because the climate control door assembly 122 is removable, the climate control door assembly 122 may be quickly and easily replaced with any compatible climate control door assembly and/or closure. In some embodiments, a tool (e.g., a lift, a jack, a winch, etc.) may be secured to the brackets 132 to vertically separate the hinges 124 and remove the climate control door assembly 122 from the front panel 108.

Turning to FIG. 2, the enclosure 100 may further include a cage 150 interiorly mounted to the front panel 108 to block the climate control opening 120. Additionally, an interior portion 152 of the climate control unit 136 may be mounted to the door panel 126. When the climate control door assembly 122 is in the closed configuration 130 (shown in FIG. 1), the cage 150 surrounds the interior portion 152. Thus, in the closed configuration 130 (shown in FIG. 1), the cage 150 may prevent damage to the interior portion 152 caused by movement of items within the enclosure 100 and/or to prevent persons temporarily within the enclosure 100 (e.g., loading and/or arranging refrigerated food) from tampering with the interior portion 152. Additionally, when the climate control door assembly 122 is in an open configuration 154, the cage 150 prevents persons outside of the enclosure 100 from tampering with items within the enclosure 100. Further, when the climate control door assembly 122 is in the open configuration 154, maintenance and/or cleaning may be performed on interior portion 152 without a technician being inside the enclosure 100.

Looking again at FIG. 2, the enclosure 100 further includes a second side wall 156 and a rear wall 158 connected to the bottom panel 102. Thus, in some embodiments, the enclosure 100 is substantially box shaped. It should be understood that the enclosure 100 may have any three-dimensional form (e.g., cylindrical, conical, polyhedral, etc.). Additional elastomeric seals 140 are mounted to the front panel 108 to sealably engage the door panel 126 in the closed configuration 130 (shown in FIG. 1). Further, the door panel 126 defines a first passage 160 and a second passage 162, which are selectively blocked by the cover panel 138.

Referring to FIG. 3, the door panel 126 additionally defines a third passage 164. The first passage 160 and the second passage 162 are between the brackets 132. The third passage 164 is located above the brackets 132. In some embodiments, the first passage 160 and the second passage 162 are substantially equal in size. In some embodiments, the first passage 160 and the second passage 162 are larger than the third passage 164.

Turning to FIG. 4, the exterior portion 134 is operably and fluidly connected to the interior portion 152 via at least one conduit 170, which extends through the third passage 164. In some embodiments, the exterior portion 134 includes a condenser and/or a compressor of the climate control unit 136. In some embodiments, the interior portion 152 includes an evaporator and/or an expansion valve of the climate control unit 136. Additionally, in some embodiments, one or more of the conduits 170 is a drain. Further, in some embodiments, the conduit 170 is insulated.

Referring to FIGS. 1, 2, and 4, in some embodiments, the interior portion 152 is a cooling portion of the climate control unit 136 and the exterior portion 134 is a heating portion of the climate control unit 136. The cooling portion (i.e., interior portion 152) is the one or more components of the climate control unit 136 that provides cooling. The heating portion (i.e., exterior portion 134) is the one or more components of the climate control unit 136 that emits heat during operation of the climate control unit 136. The cooling portion 152 may be located on a first side of the door panel 126 and the heating portion 136 may be located on a second side of the door panel 126. The first side of the door panel 126 may be located in and/or facing the interior of the enclosure 100 and the second side of the door panel 126 may be located in and/or facing the exterior of the enclosure 100.

Remaining with FIG. 4, the latch assembly 128 includes an upper hook 180, a handle 182, and a pull loop 184. The handle 182 is located along an exterior side 186 of the door panel 126. Similarly, the pull loop 184 is located along an interior side 188 of the door panel 126. The handle 182 and the pull loop 184 are operably connected to the upper hook 180 to pivot the upper hook 180 relative to the door panel 126.

Turning to FIG. 5, the latch assembly 128 further includes a lower hook 190. The handle 182 (shown in FIG. 4) and the pull loop 184 are also operably connected to the lower hook 190 to pivot the lower hook 190 relative to the door panel 126. When the climate control door assembly 122 is in the closed configuration 130 (shown in FIG. 1), the handle 182 is actuated to pivot the upper hook 180 and the lower hook 190 toward the door panel 126. While pivoting toward the door panel 126, the upper hook 180 and the lower hook 190 engage and hook onto the front panel 108 (shown in FIG. 1). Thus, the climate control door assembly 122 is tightly and sealably engaged with the front panel 108 in the closed configuration 130. The upper hook 180 and the lower hook 190 may be pivoted away from the door panel 126 by pulling the pull loop 184 and/or actuating the handle 182. Thus, the climate control door assembly 122 may be released from the front panel 108 and the closed configuration 130 from inside or outside of the enclosure 100 (shown in FIG. 1).

FIG. 6 illustrates a flow diagram depicting a method 600 to perform maintenance on the climate control unit 136 of FIGS. 1 and 3-5 via the climate control door assembly 122 of FIGS. 1-5. The method 600 starts at block 602, where the climate control door assembly 122 is unlocked from the front panel 108. More specifically, the handle 182 and/or pull loop 184 are actuated to release the upper hook 180 and the lower hook 190 from the front panel 108. The method 600 proceeds to block 604.

At block 604, the climate control door assembly 122 is opened to move from the closed configuration 130 to the open configuration 154. The method 600 proceeds to block 606.

At block 606, maintenance is performed on the climate control unit 136. More specifically, a technician may clean, repair, inspect, do upkeep, etc. on the exterior portion 134 and/or the interior portion 152 while the climate control door assembly 122 is in the open configuration 154. The method 600 then proceeds to block 608.

At block 608, the climate control door assembly 122 is closed to move from the open configuration 154 to the closed configuration 130. The method 600 then proceeds to block 610.

At block 610, the climate control door assembly 122 is locked to the front panel 108. More specifically, the handle 182 is actuated to engage the upper hook 180 and the lower hook 190 to the front panel 108. The method 600 then returns to block 602.

FIGS. 7 and 8 illustrate the enclosure 100 to show the climate control door assembly 122 in the open configuration (FIG. 7) and closed configuration (FIG. 8).

In other embodiments, other configurations are possible. For example, those of skill in the art will recognize, according to the principles and concepts disclosed herein, that various combinations, sub-combinations, and substitutions of the components discussed above can provide appropriate cooling for a variety of different configurations of motors, pumps, electronic assemblies, and so on, under a variety of operating conditions.

The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.