Configuration for a Heat Exchanger in a Temperature Controlled Case

This application is a continuation application of and claims priority under 35 U.S.C. § 120 to U.S. application Ser. No. 18/451,689, filed Aug. 17, 2023, which is a continuation of and claims priority to U.S. application Ser. No. 16/173,462, filed on Oct. 29, 2018, which claims the benefit of and priority to U.S. Provisional Application No. 62/584,231 filed Nov. 10, 2017 and entitled “Configuration for a Heat Exchanger in a Temperature Controlled Case,” the entire contents of each of which are incorporated herein by reference.

The present disclosure relates to a cooling system for a temperature controlled case. More specifically, the present disclosure relates to a configuration of a heat exchanger for a cooling system for a temperature controlled case.

Temperature controlled cases are used for the storage, preservation, and presentation of products, such as food products including perishable meat, dairy, seafood, produce, etc. To facilitate the preservation of the products, temperature controlled cases often include one or more cooling systems for maintaining a display area of the case at a desired temperature. The one or more cooling systems may include one or more cooling elements (e.g., cooling coils, heat exchangers, evaporators, fan-coil units, etc.) through which a coolant or refrigerant is circulated (e.g., a liquid such as a glycol-water mixture, etc.) to provide cooling to an internal cavity of the case (a temperature controlled space or area). As a result of the cooling, the food products or other stored items are typically maintained in a chilled state.

Temperature controlled spaces exist in many different form-factors (shapes, cross-sections, etc.) tailored to meet specific display goals. For instance, some temperature controlled spaces may have a single display deck, and be substantially open at a top horizontal plane in order to enable the placement or removal of product(s). Other temperature controlled spaces may have additional display tiers (for example, shelves or peg hooks) disposed in a generally vertical plane. Still other temperature controlled spaces may have a temperature controlled space that is oriented in a plane that is at an angle relative to vertical and horizontal planes through which products are removed or restocked. Any of these temperature controlled spaces may be open to the ambient air or selectively covered/blocked via one or more doors. Regardless of the spatial geometry of the temperature controlled space, a barrier is needed to separate the ambient surroundings and the temperature controlled space.

Cooling systems commonly circulate refrigerated air in order to both remove heat from the temperature controlled space and to establish a protective air-curtain barrier between the temperature controlled space and the ambient surroundings. The moving air is warmed as the air transits the temperature controlled space. Typically, this heat is then transferred to a tube and fin heat-exchanger in hidden, non-shopped areas of the temperature controlled case. It is desirable to minimize the functional, hidden, utilitarian areas of the temperature controlled case in order to increase product storage capacity and provide better aesthetic appeal. However, minimization of the hidden, non-shopped areas may create performance limitations that render the temperature controlled case undesirable for one or more intended purposes. For example, temperature controlled cases designed for broader application ranges or adverse ambient conditions constrain the size of the hidden, non-shopped areas, which may render the temperature controlled case undesirable for an intended merchandising display. Accordingly, there is a need for an improved heat exchanger that can overcome these limitations and retain superior refrigeration performance while reducing the hidden, utilitarian areas of the equipment.

One embodiment relates to a temperature controlled case including a housing that defines a temperature controlled space, the housing including a duct that receives circulated air; and, a heat exchanger coupled to the housing and disposed within the duct, the heat exchanger including an intake face at a non-perpendicular angle relative to an air flow direction in the duct immediately upstream of the heat exchanger.

Another embodiment relates to a heat exchanger for a cooling system for a temperature controlled case. The heat exchanger includes a cooling coil; and, a plurality of heat exchange fins coupled to the cooling coil. In one configuration, the coupled cooling coil and plurality of heat exchanges fins form a rectangular body having a primary intake face for receiving air that exchanges heat with the cooling coil, wherein the primary intake face is disposed at a non-perpendicular angle relative to a plane that is perpendicular to a direction of air flow immediately upstream of the heat exchanger.

Still another embodiment relates to a temperature controlled case. The temperature controlled case includes a housing that defines a temperature controlled space, the housing including a duct that receives circulated air; and a heat exchanger coupled to the housing and disposed within the duct, the heat exchanger including an intake face having a cross-sectional dimension greater than a cross-sectional dimension of the duct.

In the following detailed description, reference is made to the accompanying drawings, which form a part thereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here.

Referring to the Figures generally, various embodiments disclosed herein relate to a heat exchanger configuration for a temperature controlled case. In certain temperature controlled cases, air is circulated to maintain a desired temperature of a temperature controlled space. In operation, the circulated air transits the temperature controlled space whereby the air absorbs heat from the space to, in turn, cool the temperature controlled space. One or more heat exchangers are utilized to remove the heat absorbed by the circulated air before the air is then recirculated back through the temperature controlled space. According to the present disclosure, a heat exchanger is disposed in an equipment area, such as a designated duct, of the temperature controlled case, where an intake face of the heat exchanger is at a non-perpendicular angle to the air flow direction immediately upstream of the heat exchanger.

Applicant has determined that this configuration for a heat exchanger may provide several benefits. One benefit is the minimization of non-shopped areas (e.g., the duct containing the heat exchanger or other equipment area), which improves the ratio of usable refrigerated display space to the overall temperature controlled case dimension. In this regard, the size of the heat exchanger and, primarily the size of the intake face of the heat exchanger, is delinked and independent of the cross-sectional duct dimension where the heat exchanger is housed. Beneficially, this delinking provides an ability to reduce the duct dimension yet increase the intake face dimension (i.e., the cross-sectional length of the intake face versus the cross-sectional height or width of the duct) to be greater than the duct dimension. In turn, a dimension of the temperature controlled space may also be increased such that relatively more products may be stored in the temperature controlled case of the present disclosure compared to conventional temperature controlled cases. Another benefit of orienting at least one face of the heat exchanger at a non-perpendicular angle relative to the air flow immediately upstream of the heat exchanger is that such an orientation leads to less consumption of fan energy. This is due to the presence of less static pressure on the fan because of the increase in total intake face area, which results in alternate air paths around frost accumulation in the heat exchanger. As a result, users may experience a cost-savings from using less electricity as well as a prolonged life for the now less-used fan. Relatedly and as a result, defrost cycles may be required relatively less frequently as compared to typical heat exchangers. Further, these defrost cycles may utilize relatively less defrost energy compared to conventional defrost cycles because any accrued frost is thinner as the frost may be more spread out due to the increase in surface area of the intake face compared to conventional heat exchangers. These and other features and benefits are described more fully herein below.

Referring now to, a temperature controlled display deviceis shown, according to an exemplary embodiment. The temperature controlled display device(also referred to herein as a temperature controlled case and a refrigerated case) may be a refrigerator, a freezer, a refrigerated merchandiser, a refrigerated display case, or other device capable of use in a commercial, institutional, or residential setting for storing and/or displaying refrigerated and/or frozen objects. For example, the temperature controlled display devicemay be a service type refrigerated display case for displaying fresh food products (e.g., beef, pork, poultry, fish, etc.) in a supermarket or other commercial setting.

As shown, the temperature controlled display deviceincludes a housingthat defines a temperature controlled space(also referred to as a refrigerated area, temperature controlled area, or display area), a plurality of shelvesfor storing and holding products stored within the temperature-controlled space, a plurality of ducts or air ducts,, anddefined by the housingfor circulating air, a boxfor electronics (i.e., an electronics box), a cooling system, and a door. The electronics boxmay be structured as a junction box for one or more electrically-driven components of the device. The electronics boxmay also be structured to store one or more controllers for one or more components of the device. For example, the boxmay include hardware and/or logic components for selectively activating and deactivating the cooling systemto achieve or substantially achieve a desired temperature in the display area.

In various embodiments, the temperature controlled display devicemay be an open-front refrigerated display case or a closed-front display case like shown in. An open-front temperature controlled case may use a flow of chilled air that is discharged across the open front of the case to help maintain a desired temperature within temperature controlled space. A closed-front temperature controlled case, like shown in, includes one or more doors, such as a door, for accessing food products or other items stored within temperature controlled space. The one or more doors may be movable between a first position (a closed position) and a second position (an open position). In the first or closed position, like shown in, the door covers or substantially covers the opening for the temperature controlled space. In the second or position, the door is moved to be spaced apparat from the opening, such that a user may access objects stored within the temperature controlled space. Both types of display cases may also include various openings within the temperature controlled spacethat are configured to route chilled air from a cooling systemto other portions of the respective display case (e.g., via an air mover, such as fan).

The cooling systemis structured to cool the temperature controlled space. In one embodiment, the cooling systemis configured as a direct expansion system such as shown in the FIGURES. In other embodiments, the cooling system may be configured as a secondary coolant exchange system or another type of heat exchange system. All such variations are intended to fall within the spirit and scope of the present disclosure. The cooling systemincludes at least one heat exchanger(e.g. evaporator, cooling coil, fan-coil, evaporator coil, cooling element, etc.) and a unit. In the example shown, the unitis structured as a condensing unit or parallel condensing system because the cooling systemis structured as a direct heat exchange system. The condensing unit may include any typical component included with condensing units in direct heat exchange systems, such as a compressor, condenser, receiver, etc. In a secondary coolant system, the unitis structured as a chiller (e.g., heat exchanger, etc.). The chiller facilitates heat exchange between a primary refrigerant loop and a secondary coolant loop. The secondary coolant loop includes a cooling element and any other component typically included in the secondary coolant loops of secondary coolant systems. The primary refrigerant loop includes any typical components used in primary refrigerant loops of secondary coolant systems, such as a condenser, compressor, receiver, etc. In either configuration, during a cooling mode of operation, the heat exchangermay operate at a temperature lower than the temperature of the air within the temperature controlled spaceto provide cooling to the temperature controlled space.

For instance and in regard to a direct heat exchange system, during the cooling mode, the heat exchangermay receive a liquid coolant from the condensing unit. The liquid coolant may lower the temperature of the heat exchangerbelow the temperature of the air surrounding the heat exchangercausing the heat exchanger(e.g., the liquid coolant within heat exchanger) to absorb heat from the surrounding air. As the heat is removed from the surrounding air, the surrounding air is chilled. The chilled air may then be directed to the temperature controlled spaceby at least one air mover or another air handling device, shown as the fanin, in order to lower or otherwise control the temperature of the temperature controlled space. In a secondary coolant system, the coolant circulates through the heat exchangerbut does not expand (change state) within the heat exchangerlike in the direct expansion system. Thus, the heat exchangerof the present disclosure may be used with direct expansion refrigerants (e.g., HFC's or natural (CO2, propane, etc.)) and secondary coolant system coolants (e.g., CO2, glycol-water blends, Dynalene, etc.).

As mentioned above, the temperature controlled display deviceincludes a housingand a door. The dooris movably coupled to the housing. As alluded to above, the dooris movable from a position furthest from the temperature controlled space(i.e., a full open position) to a position that covers or substantially covers the temperature controlled space(i.e., a full close position). In the full or a partial open position, a user may reach into the display areato access one or more of the products stored therein.

The housingincludes cabinets (e.g., shells, etc.) shown as an outer cabinetand an inner cabinetthat include one or more walls (e.g., panels, partitions, barriers, etc.). The outer cabinetincludes a top wallcoupled to a rear wall, which is coupled to a bottom wall. The bottom wallmay be coupled to one or more support structures (e.g., legs, feet, etc.) for the case or movable elements (e.g., wheels, casters, etc.) for enabling the caseto be moved. The inner cabinetgenerally includes a top wallcoupled to a rear wallthat is coupled to a base wall. Coupling between the walls may be via any type of attachment mechanism including, but not limited to, fasteners (e.g., screws, nails, etc.), brazes, welds, press fits, snap engagements, etc. In some embodiments, the inner and outer cabinetsandmay each be of an integral or uniform construction (e.g., molded pieces). In still further embodiments, more walls, partitions, dividers, and the like may be included with at least one of the inner and outer cabinetsand. All such construction variations are intended to fall within the spirit and scope of the present disclosure.

The temperature controlled display devicedefines a plurality of ducts (e.g., channels, pipes, conduits, air ducts, etc.) for circulating chilled air. As shown and generally speaking, the outer rear walland inner rear walldefine or form a rear duct. More particularly, a divider(e.g., wall, partition, panel, barrier, etc.) and the inner rear walldefine or form the rear duct. A panelis situated between the dividerand the outer rear wall. In one embodiment, the panelis structured as an insulation panel configured to prevent or substantially prevent warmer, ambient air from transferring heat to the cooled air in the rear duct. As shown, the rear ductis in fluid communication with the bottom duct. The rear ductis also in fluid communication with a top duct. The top ductis defined or formed by the outer top walland the inner top wall. The bottom ductis defined or formed by and between the bottom walland the bottom wall. While shown as primarily rectangular in shape, it should be understood that any shape and size of the ducts may be used with the temperature controlled display deviceof the present disclosure. Furthermore, in some embodiments, at least one of the bottom, rear, and top ducts,, andmay include one or more openings (e.g., apertures) in communication with the display area. When chilled air is circulated through the ducts, a portion of the chilled air may leak out of the openings into the display areafor additional cooling.

As mentioned above, the temperature controlled display deviceis shown to include a bottom ductlocated beneath the temperature controlled space. The bottom ductmay contain one or more components of the cooling system, such as the unit. In some embodiments, the cooling systemincludes one or more additional components such as a separate compressor, an expansion device, a valve or other pressure-regulating device, a temperature sensor, a controller, a fan, and/or various other components commonly used in refrigeration systems, any of which may be stored within the bottom duct. Alternatively, the aforementioned described components may be disposed in other ducts (e.g.,and/or), in another location of the temperature controlled display device, or remote from the device. All such variations are intended to fall within the scope of the present disclosure.

With the above in mind and referring now collectively to, the heat exchangerofwith the fanremoved is shown according to an exemplary embodiment. As mentioned above and in this configuration, the heat exchangeris a part of a direct exchange cooling system. In this regard, the heat exchangeris structured to remove heat from the circulated air in order to maintain or substantially maintain a desired temperature of the temperature controlled space. Further and in this configuration, the heat exchangeris disposed within the bottom duct.

As shown, the heat exchangerincludes heat transfer fins, a cooling coil, a primary intake face, a primary outlet face, a secondary intake face wall or other blocking mechanismcoupled to the secondary intake face (not shown), and a secondary outlet face wall or other blocking mechanismcoupled to the secondary outlet face (not shown). The heat transfer finsare structured to receive the cooling coilto form a fin-coil unit. The heat transfer finsare structured to increase the thermally conductive heat transfer surface area of the heat exchangerin order to absorb a relatively greater amount of heat from the temperature controlled space. Accordingly, the heat transfer finsmay be constructed from any type of heat conductive material (e.g., aluminum, etc.). In the example shown, the heat exchangeris constructed from copper tubes (the coils) and aluminum fins. However, a variety of other construction materials may be utilized such that this arrangement is not meant to be limiting (e.g., aluminum tubes and aluminum fins, etc.). In the example depicted, the heat transfer finis shaped as a substantially rectangular shaped plate. Further, the spacing between each adjacent finin the plurality of heat transfer finsis substantially equal in value. However, in other embodiments, the size, shape (e.g., square, etc.), and thickness of each fin, as well as spacing between adjacent fins may vary to accommodate various applications. All such variations are intended to fall within the spirit and scope of the present disclosure.

As shown, the heat exchangeris structured as a rectangular cube or rectangular-shaped body having a rectangular cross-sectional shape like shown in. In other embodiments, the heat exchangerhas a square cross-sectional shape, or rhomboid cross-sectional shape. In yet other embodiments, a different cross-sectional shape may be used with the heat exchanger. The rectangular cubic structure includes six sides or faces (front, back, top, bottom, left, and ride sides or faces). In this arrangement, the left and right faces represent the longitudinal ends of the heat exchanger(thus, the left face is shown inas the face that is orthogonal when viewingand the right face is not shown)(i.e., the left face is where the coilsare shown based on the viewpoint in). The left and right faces may engage with the housingin a fluid tight manner to prevent circulated air from going around the left and right sides of the heat exchanger. In other embodiments, a non-fluid tight arrangement may exist, which permits at least some circulated air to go around the heat exchanger(i.e., between the side of the ductand the longitudinal ends of the heat exchanger).

As mentioned above, the heat exchangerincludes a primary intake face, a primary outlet face, a secondary intake face blocking mechanism, and a secondary outlet face blocking mechanism. The term “intake” when used with the faces of the heat exchangerrefers to an inlet or entry point for the air upstream of the heat exchanger. In contrast, the term “outlet” when used with the faces of the heat exchangerrefers to an outlet or exit point for the air that has passed through the heat exchanger. In turn, the “primary” face refers to the largest face (e.g., greatest surface area), while the “secondary” face refers to a relatively smaller face (e.g., a smaller surface area). With the above in mind, the primary intake faceis the vertically top face of the heat exchanger, which is proximate the temperature controlled space. The primary outlet faceis the opposite face relative to the primary intakeof the heat exchanger. Due to the rectangular cross-sectional shape, the primary intake facehas the same or substantially the same surface area as the primary outlet face.

In this example, the secondary intake and outlet faces are blocked by the blocking mechanismsand. The blocking mechanisms,(e.g., walls, covers, shrouds, etc.) perform two functions: i) control where the air may be received (the intake) and discharged (the outlet), and ii) control, at least partly, how the air flows within the duct that houses the heat exchanger. With respect to the present example, the blocking mechanismcovers or blocks the secondary intake face, which as a result, prevents intake air or substantially prevents intake air from entering the heat exchangervia the secondary intake face. Similarly, the blocking mechanismprevents or substantially outlet air from leaving the heat exchanger.

In the example shown, the blocking mechanismsandcover all or mostly all of the secondary intake and outlet faces, such that intake air cannot pass around the blocking mechanisms,in an inlet or outlet manner. In other embodiments, the blocking mechanisms,may define one or more openings (e.g., slits, circular holes, etc.) and/or be constructed smaller than the size of the secondary intake and outlet faces. In still other embodiments, the positioning of the blocking mechanisms,may be coupled to different faces than what is depicted (e.g., only a blocking mechanism on the secondary outlet face, only a blocking mechanism on the primary outlet face, etc.). In yet other configurations, no blocking mechanisms may be used. In still further configurations, some combination of the above alternative arrangements may be implemented (e.g., a smaller secondary intake face blocking mechanism than the secondary intake face and no blocking mechanism on any of the intake faces, etc.). As will be appreciated, such configurations will affect the amount and how intake air is received by the heat exchanger, the amount and how intake air circulates through the heat exchanger, and the amount and how the outlet air leaves the heat exchanger.

In the example shown, the heat exchangeris coupled to the housing, particularly the panels that define the bottom duct (e.g., bottom wall). More particularly, the heat exchanger is rotated and then coupled to the housingin the bottom duct. Because the ductalso has a rectangular cross-sectional shape (based on the viewpoint depicted in), rotating the heat exchangerand then coupling the heat exchangerto the housingin the ductfunctions to rotate the faces of the heat exchanger relative to the duct. In turn, at least one face, particularly the primary intake faceand primary outlet face, are positioned at a non-perpendicular angle relative to the air flow direction immediately upstream of the heat exchangerin the duct. Additionally, the at least one face is also in a non-parallel relationship with the wallsandthat define the lower duct. For example, the lower wallassociated with the lowest vertical surface in the temperature controlled space is at a non-parallel relationship with the primary intake face(i.e., the planeassociated with the primary intake faceis non-parallel to a parallel plane associated with the panel).

In this regard and despite the heat exchangerhaving a rectangular external and overall shape, coupling of the heat exchangerto at least one panel in the ductis done to rotate the orientation of the heat exchangersuch that at least one face is at or substantially at a non-perpendicular angle relative to the air flow direction in the ductimmediately upstream of the heat exchanger. Coupling of the heat exchangerin this manner may be done via a variety of different methods: for example, different sized legs or brackets may be used to change or control the relative heights of an end of the heat exchanger proximate the vent(i.e., the intake air side) versus the outlet side proximate the rear duct; the legs may be adjustable in height (e.g., via a threaded rod, etc.) such that technicians or other personnel can adjust the relative heights of all the legs to control and modify after installation the orientation of the heat exchangerin the duct; etc. It should be understood that similar types of coupling mechanisms may be used when the heat exchangeris disposed in another, non-lower horizontal duct of the temperature controlled case, such as the rear vertical duct. In each scenario, changing or controlling the position of the heat exchangerrelative to the ducts that house the heat exchangerenables the at least one face to be at a non-perpendicular angle relative to the air flow direction immediately upstream of the heat exchanger.

In this regard and as shown, the primary air intake faceof the heat exchangeris at a non-perpendicular angle relative to the upstream air flow direction in the duct. Conventionally, intake faces of heat exchangers are disposed perpendicular to the upstream air flow direction. Applicant has determined many advantages of disposing the primary air intake face among other faces of the heat exchanger non-perpendicular to the air flow direction immediately upstream of the heat exchanger. In this regard, the phrase “non-perpendicular to the air flow direction immediately upstream of the heat exchanger” means that the mentioned face (e.g., primary intake face, etc.) is oriented at a non-perpendicular angle to the air flow direction within the duct immediately upstream of the heat exchanger. The air flow direction can be determined by the overall orientation of the relevant duct. For example, the ductis a substantially horizontal oriented duct such that the substantially horizontal direction is the air flow direction. In contrast, the ductis a substantially vertically-oriented duct, such that the air flow direction is substantially vertical in nature. In some embodiments, the duct may be purely horizontal or vertical, such that the air flow in these ducts is at an angle and the at least one face of the heat exchanger is moved or rotated to be non-perpendicular to this air flow direction. This definition excludes any air flow changes of direction that may occur when, e.g., the air flow enters the duct housing the heat exchanger. Additionally, “non-perpendicular” means an angle between and including zero (0) degrees to eighty-nine (89) degrees, where “approximately” in this context means+/−0.5 degrees.

Therefore and based on the view shown in, circulated air enters the ductvia the vent, which as shown means the air goes from a downward vertical direction to a leftward horizontal direction. Thus, the transition is not used to determine non-perpendicularity; rather, the immediate upstream air flow direction is parallel to the orientation of the lower wall, which is perpendicular to the plane. In this example, the orientation of the lower wallis at an anglerelative to a horizontal plane. In the depicted embodiment, the angleis approximately three (3) degrees. Beneficially, by placing the lower wallat this angle as opposed to being perfectly horizontal, drainage of various items in the duct(e.g., defrost water, spilled food merchandise, liquids used when cleaning the case, etc.) is promoted (e.g., to a waste outlet pipe). This slope is known as a drainage slope. Turning back to heat exchanger, a planeis provided parallel to the primary intake face(more particularly, coplanar with the intake face), which is shown to intersect the planeat an angle. In the example shown, the planeforms an approximate five (5) degree angle relative to a horizontal plane. As such, the angleis non-perpendicular relative to the plane, which is perpendicular to the air flow direction immediately upstream of the heat exchanger. In the example shown, the angleis approximately eighty-eight (88) degrees. In other embodiments, a different non-perpendicular angle may be implemented with the primary intake facerelative to at least one of the plane that is perpendicular to the air flow direction immediately upstream of the heat exchangeror to a panel/wall that defines the duct (e.g., wallsor). In this regard, the angle of the primary intake facerelative to the horizontal plane may vary in other implementations (e.g., ten degrees, fifteen degrees, etc.) (a different angle relative to the horizontal plane than five (5) degrees). As such, the angle—the angle between the planethat is coplanar to the primary intake faceand the planethat is perpendicular to the immediate upstream air flow direction—can vary greatly in different embodiments. Turning back to the heat exchangerand due to the rectangular overall shape of the heat exchanger, each of the opposite-oriented faces of the heat exchanger (e.g., primary intake faceand primary outlet face) are parallel to each other. As such, each face in each pair of parallel faces is at the same angle relative to the upstream air flow in the duct.

In the example shown, the primary intake faceis at a non-perpendicular angle, shown as angle, to the air flow direction immediately upstream to the heat exchangerin the duct. In particular, the angleof the primary intake faceis “negative” relative to the planethat is perpendicular to the upstream air flow direction that is immediately upstream of the heat exchanger. In this regard, “negative” and “positive” refer to how the face is oriented with respect to the plane that is perpendicular to the immediate upstream air flow direction relative to the heat exchanger in the duct (in this example, plane) whereby “negative” refers to the face being oriented away from the perpendicular plane and “positive” refers to the face being oriented towards the perpendicular plane. Here, the primary intake faceis at a “negative” angle. In this regard and relative to a horizontal plane, the primary intake faceis at an approximate one-hundred and seventy-two (172) degree angle (172=180 degrees minus (5 degrees for the angle of the planerelative to a horizontal plane plus 3 degrees for the angle of the lower wallrelative to the horizontal plane)). In comparison and if the blocking mechanismwere removed from the secondary intake face, the secondary intake face would be at a positive angle relative to the perpendicular plane. All variations of positive and negative angles for all of the faces of the heat exchanger are intended to fall within the spirit and scope of the present disclosure.

With the above in mind, operation of the heat exchangerin connection with the cooling systemand the benefits associated therewith may be described as follows. As heat is removed from the surrounding air via the heat exchanger, the surrounding air is chilled. While the chilled air may be directed to temperature controlled spaceby at least one air mover or another air flow device (e.g., fan), the chilled air may also be circulated through the ducts,, andby the fan. Via the motive force from the fan, the chilled air is first directed, guided, forced, otherwise pushed or moved to the rear duct. The rear ductguides the chilled air to the top duct. The top ductguides the chilled air to a discharger. The discharger(e.g., diffuser, etc.) provides or discharges the chilled air to form or at least partially form an air curtain. At least part of the air in the air curtainmay be received by a receptacle, shown as a ventthat is in fluid communication with the bottom duct. The received air may then be pushed to the heat exchangerby the fan. The pushed air impacts the secondary face blocking mechanism. Due to the blocking mechanismand lower wallof the bottom ductengaging to form a substantially fluid-tight seal, the pushed air is forced to move upwards towards the upper wall(i.e., towards the temperature controlled space). The upward moving air may then impact the upper wall(i.e., the surface proximate the heat exchanger), which redirects the air towards the primary air intake face. However, some of the upward moving air may simply migrate to the primary air intake facewithout impacting the upper wall. In any event, this air is received by the heat exchangervia the intake face, such that heat is removed from the air received by the heat exchanger. The cooled air is then discharged via the primary outlet face. In this example, the discharge direction is towards the lower wall. The discharged chilled air may either impact the lower wall or not; in either case and due to the motive force, the chilled air is then directed to the rear duct. In this example, each of the intake faceand discharge faceis at a non-perpendicular angle relative to the air flow direction immediately upstream of the heat exchanger.

In the example depicted, the heat exchangerincludes a primary intake face of 12.75″, which is disposed in the ductwith a smaller 6.5″ height (from the surface of the lower wallproximate the heat exchangerto the surface of the wallproximate the heat exchanger). Thus, a length of the faceis longer than a vertical height of the duct. More generally and as described herein, the cross-sectional length (the length of the facethat is shown inas contrasted with the length that goes into the page of) of the primary intake face of the heat exchanger is greater than the cross-sectional height (in the case of a heat exchange positioned in a horizontal duct) or width (in the case of the heat exchanger positioned in a vertical duct) of the duct that receives the heat exchanger. The height and widths of the ducts relative to the length of the primary intake faces are shown in the FIGURES herein. As mentioned above, panels (blocking mechanismsand) were installed to block air flow on the short/secondary intake/outlet faces (3.25″) sides of the heat exchanger and to direct the air flow through the larger (12.75″) primary intake and outletandfaces. As mentioned above, this configuration was oriented at a 5-degree angle from the duct structure formed between the lower wall and upper wall of the duct(thus, an 8-degree angle relative to the horizontal plane due to the 3-degree drainage slope angle). Based on the aforementioned operational description, the heat exchangerwas oriented to intake air flow from vertically above and have the air flow exit towards the bottom wall (a vertically downward direction based on the viewpoint in), where the air flow turned to move rear ward and again parallel to the duct.

A first advantage is that the duct dimension that houses the heat exchanger no longer constrains the intake face dimension of the heat exchanger. The intended primary air intake face can thus be increased to a dimension greater than the non-shopped duct cross-sectional height/dimension in which the heat exchanger resides (i.e., the vertical height of the duct from the lower wall to the upper wall). A larger intake face reduces the overall air flow-resistance of a heat-exchanger versus a typical heat exchanger. A second advantage is that the lowered air flow resistance reduces energy consumption of the air-mover, such as the fan, which generates the pressure differential circulating the air. Additionally, fans generate unwanted heat energy within the refrigerated space, so reduced fan energy can in turn lower the refrigeration demand.

A third advantage is that the larger intake face compared to conventional heat exchangers increases robustness of the heat exchanger versus ice accumulation. In operation, air entering the heat exchanger contains moisture entrained from the ambient which is preferentially attracted to the cold surfaces of the heat exchanger. The moisture collects as ice crystals on the heat exchanger operating at or below the freezing-point of water. As the ice grows in thickness it creates an insulating barrier between the heat exchanger and air flow, thereby diminishing heat transfer efficiency. Simultaneously, the ice growth reduces the space between heat exchanger passageways and increases the air flow resistance, which increases energy consumption of the fan or other air-mover. To address the ice accrual, manufacturers create defrost schedules for their refrigerated display cases and the heat-exchanger therein. Beneficially, the heat exchanger of the present disclosure can be designed for a certain lowered pressure drop that enables overall lowered air-velocity in the display case, thereby entraining less moisture into the refrigerated air-curtain by choosing a non-perpendicular angle of the primary air intake face relative to the air flow immediately upstream of the heat exchanger. In this regard and for heat exchangers that are otherwise constructed the same, and which encounter the same air volume moving at similar air-velocity with same moisture content, the larger intake face of the heat exchanger of the present disclosure has a slower rate of ice accumulation because the same moisture content is distributed over a larger intake face. Due the slower ice accumulation rate, the heat exchanger of the present disclosure may be operated longer between defrost cycles or be given defrosts as frequently as a conventional heat exchanger but for a shorter time duration. Either method sums to a lower amount of total defrost time per twenty-four hour period. Lowered overall defrost time is desirable since the refrigeration is shut off during defrost cycles and the entire case drifts warmer in temperature, though at a different rate from the localized heat exchanger area. The shorter overall amount of defrost time may disturb product temperature less plus allow the temperature controlled case to pull temperatures down more efficiently upon re-entering refrigeration (it is quicker and requires less energy to re-obtain the desired refrigeration set-point having started from a less disturbed, colder temperature at end of defrost).

A related fourth advantage is that the heat exchangeris then more resistant to ice accumulation and, in turn, is more flexible and desirable for an end user. For example, the temperature controlled caseand heat exchangermay be configured with extra resistance to ice-accumulation as a means to offer a broader operating range in order to perform in harsh environments (e.g., stores with elevated ambient humidity levels or greater shopping traffic, which cause higher moisture levels in the return air). As another example, the heat exchanger might be configured for a broader range of application set-points thereby allowing the conversion of a case to display different product types (e.g., a case originally used for dairy may be reconfigured and capable to cool fresh meat should a user determine later need for more meat display in the store).

A fifth advantage is that the minimization of non-shopped areas (i.e., the duct containing the heat exchanger) improves the ratio of usable refrigerated display to the overall temperature controlled case size. As an example, for a heat exchanger of the present disclosure mounted in a rear wall vertical duct, a size reduction in the duct may reduce the amount of required floor space for the temperature controlled case (seediscussed below). For a heat exchanger of the present disclosure mounted in a horizontal duct (like in), the overall temperature controlled case size may be unchanged but the temperature controlled spacesize may be increased. Additionally, a reduction in the size of the horizontal duct may allow the equipment maker to vertically translate and lower a front sill height and perishable display deck(s) by the same amount as the duct reduction. This may promote easier product access for store workers, consumers (especially disabled individuals), and provide bettered product viewing.

Referring now to, the heat exchangeris disposed in a lower horizontal ductof a closed-front temperature controlled case, according to exemplary embodiments. The configuration inis identical to that shown inexcept for the blocking mechanisms being removed and the differences described below. As shown, the heat exchangerincludes a primary intake face, a primary outlet face, a secondary intake face, and a secondary outlet face. Like in, an induced air flow configuration is shown in(i.e., the fanis disposed downstream from the heat exchanger). As shown, a pair of bracketsand(e.g., feet, braces, support structures, etc.) couple the heat exchangerto the housing, particularly the inner surface of the bottom wall, within the bottom horizontal duct. The bracketsandare shown to have a height that varies longitudinally in order to dispose the primary intake faceat a non-perpendicular angle to the air flow direction immediate upstream of the heat exchanger. In this configuration, the primary air intake faceis disposed at an approximate five (5) degree angle relative to the inner surface of the bottom wall. This shown as angle. In this regard, the air flow in the horizontal ductis a horizontal direction, such that the primary intake faceis at a non-perpendicular angle relative to the air flow direction in the duct. Of course and as described above, in other embodiments, different coupling mechanisms may be utilized to control the orientation of the heat exchangerwithin the duct(i.e., to be at different angles other than five degrees).

The air flow through the heat exchangerofdiffers from that depicted in. In this regard, no blocking mechanisms are utilized to block one or more intake/outlet faces. Further, intake air is directed vertically downward and toward the bottom wallwhere it then is directed vertically upward toward the face. Simultaneously, intake air can also be received by the secondary intake face. The air is chilled through the heat exchangerand discharged via the primary outlet facetowards the upper walland via the secondary outlet face. Applicant has determined that the addition of the faces previously blocked inas a secondary intake and secondary outlet facesandis a viable configuration capable of transferring heat from the moving air to the heat exchanger. The further advantage of this configuration is that the multiple intake faces increase the effective intake face dimension. Using the same sizes of the faces of the heat exchanger inand because both the primary (12.75″) and secondary (3.25″) intake faces are active (i.e., able to receive intake air), this configuration has a relatively larger intake face surface area compared to that of(i.e., 16″ total intake dimension). In this configuration, the air stream can continue to maintain a vector direction parallel to the ductwhile going through the heat exchanger. That said, the primary intake faceremains at a non-perpendicular angle to the upstream air vectors, and as mentioned above, in this configuration crosses the primary intake face at direction 5-degrees from parallel.

With reference to, a decrease in duct dimension heightis shown. In this regard and as mentioned above, positioning the primary air intake face of the heat exchanger at a non-perpendicular angle relative to the air flow direction immediately upstream from the heat exchanger may enable decreasing the size of the duct that houses the heat exchanger. This size reduction is shown by reference numberin.

Referring now to, a heat exchanger disposed in the rear vertical ductin a vertically-oriented temperature controlled caseis shown, according to an exemplary embodiment. The temperature controlled casemay have a similar configuration to that which is shown in. However, here, the heat exchangeris disposed in the back vertical ductand the fanis disposed upstream of the heat exchanger. Thus, a forced air relationship is provided in the temperature controlled caseof.

The heat exchangermay have a similar configuration as the heat exchanger. In this regard, the cooling system of the temperature controlled caseofmay be a direct expansion cooling system, such that a similar function may be implemented with the heat exchanger. However, a different reference number is used to denote a different structure that is implemented with the heat exchangerin order to couple the heat exchangervertically in the duct.

As shown, the heat exchangerincludes a pair of primary intake facesand a pair of primary outlet faces. In this regard, the cross-sectional length (as shown in) of each face in each pair is equal or substantially equal to each other. In other embodiments, different lengths may be implemented with the four intake/outlet faces. Further, blocking mechanisms, like blocking mechanismsand, may also be coupled to one or more faces. In the example shown, no blocking mechanisms are used with any of the intake/outlet faces.

As shown, each of the intake and outlet facesandis at a non-perpendicular angle relative to the air flow direction immediately upstream to the heat exchanger, which is perpendicular to the horizontal plane. In particular, the each of the intake facesis at an anglerelative to the plane, whereby the planeis perpendicular to the air flow direction immediately upstream of the heat exchanger. In the example depicted, the angleis approximately equal to forty-five (45) degrees, where approximately is equal to +/−0.5 degrees. Based on Applicant's research, the heat exchanger can be just as effective whether the primary intake face is between the insulated wall and the airstream (i.e., the left “X”) versus from the air stream to the metal panels that separate the duct from the shopped space.

The heat exchanger embodiments of the present disclosure are applicable across a wide range of equipment that circulates air to maintain a desired temperature of a refrigerated space. As example, single display deck cases, cases with multiple display decks, cases with doors (whether vertical, horizontal, or at another angle), and open-cases all could derive benefits from the heat exchanger embodiments of the present disclosure. The heat exchanger embodiments of the present disclosure are applicable whether the heat exchanger and duct are in a vertical plane (e.g.,), a nominally horizontal plane (e.g.,), and/or any other orientation or area of the case. The heat exchanger embodiments of the present disclosure can be used independent of, or in conjunction with, other existing technologies such as multiple air-curtains, single air curtains, and structures that direct outlet air flow to certain areas of the shopped/temperature controlled space or certain sub-ducts of the case. Moreover, the heat exchanger embodiments of the present disclosure apply regardless of the number of heat exchangers within the temperature controlled case or cases (i.e., one large heat exchanger versus multiple smaller heat exchangers). The fan(s), or other air movers, may be installed upstream the heat exchanger (forced air)(e.g.,), downstream from the heat exchanger (induced air flow at heat-exchanger) (e.g.,), or in multiple locations before, after, or both before and after the heat exchanger embodiments of the present disclosure. Air movers may be installed in a section of intersecting duct that communicates the air flow to or from the duct section housing the heat exchanger. As an example,depicts a case where the upstream air mover resides in a horizontal duct at case bottom (i.e. from insulated tank to display deck panels) and the air mover forces air around a turn in the duct work and into an intersecting duct section that runs vertically. The heat exchanger resides within the vertical duct section (between insulated rear wall and metal baffles that define rear of the shopped space). As described above, the heat exchanger may be deployed with the primary intake face oriented at either a positive or negative rotation angle from the upstream airflow.

It should be understood that the terms “refrigerant” and “coolant” are used interchangeably herein. In this regard, Applicant contemplates that a wide variety of coolant or refrigerant types may be used with the heat exchanger of the present disclosure.

It should be noted that references to “front,” “rear,” “upper,” “top,” “bottom,” “base,” and “lower” in this description are merely used to identify the various elements as they are oriented in the Figures. These terms are not meant to limit the element which they describe, as the various elements may be oriented differently in various embodiments.

Further, for purposes of this disclosure, the term “coupled” or other similar terms, such as “attached,” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature and/or such joining may allow for the flow of fluids, electricity, electrical signals, or other types of signals or communication between the two members. Such joining may be achieved directly with the two members or the two members and any additional intermediate members being attached to one another and the two members. For example and for the purposes of this disclosure, component A may be referred to as being “coupled” to component B even if component C is an intermediary, such that component A is not directly connected to component B. On the other hand and for the purposes of this disclosure, component A may be considered “coupled” to component B if component A is directly connected to component B (e.g., no intermediary). Such joining may be stationary or moveable in nature. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

It is important to note that the construction and arrangement of the elements of heat exchanger provided herein are illustrative only. Although only a few exemplary embodiments of the present disclosure have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible in these embodiments without materially departing from the novel teachings and advantages of the disclosure. Accordingly, all such modifications are intended to be within the scope of the disclosure.

The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present disclosure as expressed in the appended claims.