Thermal Frame with Insulating Backing Member

This application is a continuation application of and claims priority under 35 U.S.C. § 120 to U.S. application Ser. No. 18/508,074, filed on Nov. 13, 2023, which is a continuation application of and claims priority to U.S. application Ser. No. 17/327,643, filed on May 21, 2021, now U.S. Pat. No. 11,832,740, the entire contents of which are incorporated herein by reference.

This invention relates to temperature controlled storage devices, and doors and associated frames used in such devices.

Refrigerated enclosures are used in commercial, institutional, and residential applications for storing and/or displaying refrigerated or frozen objects. Refrigerated enclosures may be maintained at temperatures above freezing (e.g., a refrigerator) or at temperatures below freezing (e.g., a freezer). Refrigerated enclosures have one or more doors or windows for accessing and viewing refrigerated or frozen objects within a temperature-controlled space. Refrigerated enclosures typically include a frame that supports the doors or windows.

Condensation on sealing surfaces of doors of refrigerated enclosures and their associated frames can impair sealing and decrease energy efficiency. Formation of condensation (frost formation) on door also affects visibility to product placed inside enclosure and may cause customer dissatisfaction. Electric heater wires are sometimes employed in the thermal frames of commercial refrigerated enclosures to inhibit condensation. However, electrical heaters can use a significant amount of electrical power. Excess reliance on such heater wires may make ever more stringent government regulations on energy efficiency more difficult to meet.

One aspect of the invention features a frame for a refrigerated enclosure including a main frame member, a backing member, and a contact plate. The main frame member includes a base, a middle wall, and a forward flange. The base has rear wall and an interior wall. The backing member and the contact plate are coupled to the main frame member. The backing member includes a rear leg that couples on the rear wall of the base of the main frame member and an interior leg that couples on the interior wall of the base of the main frame member. The interior leg and the rear leg each include a thermal insulating portion. The interior leg includes a front portion that couples with the contact plate.

In some implementations, the thermally insulating portions of the interior leg and the rear leg are integral to one another and form an L-shape.

In some implementations, the interior leg retains an edge of the contact plate.

In some implementations, the front portion of the interior leg extends forward to a front plane of the contact plate.

In some implementations, the thermally insulating portions of the rear leg and the interior leg include a foam material.

In some implementations, the backing member inhibits condensation on one or more surfaces of the frame.

In some implementations, a portion of the contact plate extends in an interior direction over at least a portion of the interior leg of the backing member.

In some implementations, the frame includes a zipper coupled to the interior leg of the backing member.

In some implementations, the backing member further includes a bracket that holds the thermally insulating portions of the backing member on the base of the main frame member.

In some implementations, the bracket of the backing member and the base of the main frame member each include an engaging portion on the interior side of the base. The engaging portions engage one another to couple the backing member to the base.

In some implementations, the backing member includes an exterior leg, wherein the exterior leg is configured to extend forward from the rear leg along an exterior surface of the base of the main frame member.

In some implementations, the frame includes a thermally insulating member between the main frame member and the exterior leg of the backing member.

In some implementations, the backing member includes a bracket having an exterior portion that couples to a body of the refrigerated enclosure. The base frame member couples to the exterior portion of the bracket.

In some implementations, the base includes one or more channels that hold one or more heater wires. The channel(s) include an opening at least partially facing the contact plate.

In some implementations, the forward flange is configured to absorb heat from ambient air to inhibit condensation on the frame.

Another aspect of the invention features a temperature-controlled enclosure for displaying cold items. The temperature-controlled enclosure includes a body, a frame assembly, and one or more doors. The body includes a front opening and defines an interior space of the enclosure. The frame assembly is coupled in the front opening of the body. The frame assembly includes a frame segment having, in cross-section, a main frame member, a backing member, and a contact plate. The rear leg couples on the rear wall of the base of the main frame member, and the interior leg couples on the interior wall of the base of the main frame member. The interior leg and the rear leg each comprise a thermally insulating portion. A front portion of interior leg of the backing member extends forward to a front plane of the contact plate. The gasket forms a seal between the frame assembly and the door when the door is closed. A portion of the backing member of the frame segment contacts at least a portion of a rear surface of the gasket or a rear surface of the contact plate when the door is closed.

In some implementations, an inner surface of the interior leg of the backing member is interior to an inner surface of the gasket when the door is closed.

In some implementations, an inner surface of the backing member is substantially aligned with an inner surface of the gasket when the door is closed.

In some implementations, a front surface of the backing member and a rear surface of the door define a channel interior to an inner surface of the gasket.

In some implementations, the forward flange is configured to absorb heat from the ambient air to inhibit condensation on the frame.

In some implementations, the temperature-controlled enclosure includes an insulating member between the forward flange and a front surface of the body of the enclosure.

Another aspect of the invention features a frame for a refrigerated enclosure. The frame includes a frame segment having, in cross-section, a main frame member, a backing member, and a contact plate. The main frame member includes a base having a rear wall and an interior wall.

The backing member includes a rear leg that couples on the rear wall of the base of the main frame member, and an interior leg that couples on the interior wall of the base of the main frame member. The interior leg and the rear leg each include a thermal insulating portion. The thermally insulating portions of the interior leg and the rear leg form an L-shape. The contact plate extends inwardly over at least a portion of the front portion of the backing member.

The concepts described herein may provide several advantages. For example, implementations of the invention may provide a frame with improved thermal efficiency. Implementations may prevent or minimize condensation build up on door sealing surfaces. Implementations may provide for a more positive thermal seal between a thermal frame and a door.

The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

Like reference symbols in the various drawings indicate like elements.

In some implementations, a frame segment assembly includes an L-shaped backing member that fits on the back and interior faces of an inner member of the frame. The backing member includes a thermally insulating member for reducing thermal transference between the frame and the interior space of the enclosure. The insulating member can be an L-shape. In some implementations, the interior leg of the L-shaped backing member runs from the back of the frame to a rear surface of the door gasket. The contact plate of the frame can extend over the interior leg of the backing member.

show an exemplary refrigerated enclosure. Refrigerated enclosuremay be a refrigerator, freezer, or other enclosure defining a temperature-controlled space. In some implementations, refrigerated enclosureis a refrigerated display case. For example, refrigerated enclosuremay be a refrigerated display case or refrigerated merchandiser in grocery stores, supermarkets, convenience stores, florist shops. and/or other commercial settings to store and display temperature-sensitive consumer goods (e.g., food products and the like). Refrigerated enclosurecan be used to display products that must be stored at relatively low temperatures and can include shelves, glass doors, and/or glass walls to permit viewing of the products supported by the shelves. In some implementations, refrigerated enclosureis a refrigerated storage unit used, for example, in warehouses, restaurants, and lounges. Refrigerated enclosurecan be a free standing unit or “built in” unit that forms a part of the building in which refrigerated enclosureis located.

Refrigerated enclosureincludes a body. Bodyincludes a top wall, a bottom wall, a left side wall, a right side wall, a rear wall (not shown), and a front portiondefining a temperature-controlled space. Front portionincludes an opening into the temperature-controlled space. Thermal frameis can be mounted at least partially within the opening. Thermal frameincludes a plurality of perimeter frame segments (i.e., a header or top frame segment, a sill or bottom frame segment, a left side frame segment, and a right side frame segment) forming a closed shape along a perimeter of the opening. In some implementations, thermal frameincludes one or more mullion frame segmentsdividing the opening into multiple smaller openings. For example,illustrates a three-door assembly with a pair of mullion frame segmentsextending between top frame segmentand bottom frame segmentto divide the opening into three smaller openings. Each of the smaller openings may correspond to a separate doorof the three-door assembly. In other implementations, mullion frame segmentsmay be omitted. For example,illustrates a one-door assembly wherein thermal frameincludes perimeter frame segments-but not mullion frame segments. In some implementations, thermal frameincludes include top frame segmentand bottom frame segmentwith no side frame segmentsor. In such implementation, thermal framemay include one or more mullion frame segmentsdepending. for example, on the size of the refrigerated enclosure in which thermal frameis to be installed and the number of doors.

Refrigerated enclosureincludes one or more doorspivotally mounted on the thermal frameby hinges. In some implementations, the doorsare sliding doors configured to open and close by sliding relative to the thermal frame. The example doorsillustrated ininclude panel assembliesand handles. Referring to, thermal frameis includes a series of contact plates. Contact platesare be attached to a front surface of thermal frameand provide a sealing surface against which doorsrest in the closed position. For example, doorsmay include a gasket or other sealing feature around a perimeter of each door. The gaskets may employ a flexible bellows and magnet arrangement, which, when the doorsare closed, engage contact platesto provide a seal between doorsand thermal frame. The thermal frames provide a thermally conductive path from the frame segments-, for maintaining maintains the temperature of the contact platesat or close to the temperature of the external environment (e.g., the environment outside of the refrigerated enclosure) and to aid in preventing condensation from forming on the contact plates. Preventing condensation on the contact plates may provide for a more positive seal between the contact platesand a magnetic gasket on the door, thereby improving the thermal properties of the refrigerated enclosure.

illustrates a cross-sectional view of the refrigerated enclosuretaken along the line-in.illustrates the pair of side wallsandof the refrigerated enclosureextending rearward from front portion, and a rear wallextending between side wallsandto define a temperature-controlled spacewithin the body.

In, refrigerated enclosureis shown as a two-door assembly with a pair of doorspositioned in an opening in front portion. Refrigerated enclosuremay have two doors(as shown in), a lesser number of doors(e.g., a single door as shown in), or a greater number of doors(e.g., three or more doors as shown in). Each doorincludes a panel assemblyand a handle. Applying a force to handlecauses the corresponding doorto rotate about hingesbetween an open position and a closed position. In some implementations. panel assemblyis a transparent or translucent panel assembly through which items within temperature-controlled spacecan be viewed when doorsare in the closed position. For example, panel assemblyis shown to include a plurality of transparent or translucent panelswith spacestherebetween. The spacescan be sealed and filled with an insulating gas (e.g., argon) or evacuated to produce a vacuum between panels. In some embodiments. panel assemblyincludes opaque panels with an insulating foam or other insulator therebetween. Doorsinclude gasketsattached to a rear surface of doorsalong an outer perimeter of each door. Gasketsare configured to engage a sealing surface of the contact platesand(referred to collectively as contact plates) when the doorsare in the closed position, and to thereby provide a seal between doorsand contact plates.

The perimeter frame segments-of the thermal frameare coupled to the bodyof the refrigerated enclosureby mounting brackets. Mounting bracketscan be secured to perimeter frame segments-using one or more connection features (e.g., flanges, notches, grooves, collars, lips, etc.) or fasteners (e.g., bolts, screws, clips, etc.) and may hold perimeter frame segments-in a fixed position relative to the bodyof the refrigerated enclosure.

Although only two perimeter frame segments-are shown in, other perimeter frame segments (e.g., header/top frame segmentand sill/bottom frame segment) may be configured in a similar manner. For example, top frame segmentand bottom frame segmentmay be coupled to the bodyof the refrigerated enclosureby mounting brackets.

The perimeter frame segment assembly includes a perimeter frame segment (i.e., one of frame segments-), a mounting bracket, and a contact plate.

One or more mullion frame segmentsextend vertically between top frame segmentand bottom frame segment. A top portion of mullion frame segmentis fastened to a top frame segmentand a bottom portion of mullion frame segmentis fastened to a bottom frame segment.

In some implementations, the frame assembly includes an L-shaped thermally insulating backing member that fits on the back and interior faces of the main frame member of a mounting frame for the door of a commercial refrigerated enclosure. The backing member includes insulation for reducing thermal transference between the frame and the interior space of the enclosure. The interior leg of the L-shaped backing member may run from the back of the frame to the trailing edge of the door gasket. The contact plate of the frame can extend an interior direction over the interior leg of the backing member.

illustrates refrigerated enclosure with a door in a closed position on a frame assembly according to implementations of the present disclosure. Refrigerated enclosureincludes doorand frame segment assembly. Dooris closed on frame segment assembly. For illustrative purposes, only a short segment of the door and a corresponding segment of frame segment assembly shown. Nevertheless, the cross section shown incan continue around the entire perimeter of window panel assembliesand the corresponding perimeter of the frame assembly.

Doorincludes window panel assemblyand gasket. Gasketmay run continuously around the perimeter of door. In various implementations, gasketcan be a single continuous piece, or can include a set of gasket components, with one gasket component on each of the edges of the perimeter. Gasketcan be made of a resilient material, such as synthetic rubber.

is a perspective view of a frame segment assembly according to an illustrative implementation. Frame segment assemblyincludes main frame member, backing member, and contact plate. Main frame memberincludes base, middle wall, and forward flange.

Backing memberis coupled to main frame member. Interior legof backing memberis against interior wallof main frame member. Rear legof backing memberis against rear wallof main frame member. Exterior wallof bracketmay run along an outer side wallof baseand middle wall.

Backing memberincludes bracketand insulating member. In the implementation shown in, insulating memberhas an L-shape with one leg of the insulating member forming part of rear legof backing member, and another leg of the insulating member forming a part of interior leg. Over a portion of exterior wall, insulating memberis disposed between exterior wallof bracketand the middle wallof main frame member.

In some implementations, the interior leg of an insulating member extends all the way to a contact plate or gasket. In some implementations, the interior leg of insulating member extends more than half way from the rear edge of baseto the contact plate or more than half way from the rear edge of baseto rear surface of the gasket. In one implementation, a rear leg extends all the way across the rear surface of base. In one implementation, a rear leg extends more than half way across the rear surface of base. In some implementations, a rear leg extends all the way to a bracket in contact with the body of a refrigerated enclosure.

is a perspective view of a door according to an illustrative implementation. Window panel assemblyincludes panelsand housing assembly. Housing assemblysurrounds and supports the edges of window panels. Housing assemblyincludes outer housing memberand rear retaining member. Rear retaining membercan snap together with outer housing memberby way of complementary engaging portions,. Window panelsare stacked between front retaining rimof outer housing memberand rear retaining rimof rear retaining member.

is a cross-sectional view of a door in a closed position on a frame assembly according to an illustrative implementation. The outer end of contact plateis supported by main frame member. Contact platemay be secured in place with a retaining clip(e.g., a zipper strip or other suitable fastening device). Retaining clipmay be coupled to bracketby an engagement feature(e.g., a flange, a notch, a lip, a collar, a groove, etc.) of bracketof backing member.

In the example shown in. bracketextends to the plane of the front of baseof main frame member. Front surfaceof bracketcontacts the rear surface of contact plate. Bracketis secured to the interior side of baseof main frame memberby way of engagement of projectionof basein retaining grooveof bracket.