Climate Control Door System and Methods

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.

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.

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.

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 enclosurethat is configured with a removable climate control unit(e.g., air conditioner unit) for selectively controlling the climate of the interior of the enclosure. As described in greater detail herein, the climate control unitmay be mounted in a door assemblyto facilitate removal, adjustment, modification and/or maintenance to the climate control unitor the enclosure. The door assemblyis mounted on an exterior wall of the enclosureand configured for pivotable rotation within an opening or portdefined through the exterior wall of the enclosure. The climate control unitis mounted to the door assembly, which is configured to pivot between a closed position (sec.) in which the openingis covered by the door assemblyand an open position (see) in which the openingis uncovered. Pivoting the door assemblyinto the open position extracts the climate control unitfrom the enclosureand pivoting the door assemblyinto the closed position inserts the climate control unitinto the enclosure. The structural components, operation and configurations of the disclosure are described in additional detail below.

The enclosuremay also be configured for any suitable application. In some embodiments, the enclosuremay 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 enclosuremay have any suitable size and configuration depending on the desired application.

illustrates an enclosureaccording to an embodiment. In some embodiments, the enclosureincludes a bottom panelopposite a top paneland connected to a first side paneland a front panel. The first side paneldefines a primary access opening. A primary access dooris pivotably connected to the first side panelto selectively and securely close the primary access opening. The primary access openingprovides access for a user to enter an interior spacedefined by the enclosure. The user may thus, for example, deposit and remove goods from the enclosure.

Remaining with, the front paneldefines a climate control opening. A climate control door assemblyis pivotably connected to the front panelto selectively, sealably, and securely close the climate control opening. More specifically, a plurality of hingesswingably connect a door panelto the front panel. The hingesare separable, thus the climate control door assemblyis removable from the front panel. Further, a latch assemblymounted in the door panelselectively locks the door panelto the front panelin a closed configuration. At least one bracketis mounted to and extends from the door panelto support an exterior portionof a climate control unit. Additionally, a cover panelis mounted to the door panelbetween the brackets. Elastomeric sealsare also mounted to the door panelto sealably engage the front panel. In some embodiments, the bracketsextend beyond a lower edgeof the door panel.

Looking still at, it should be understood and appreciated that by removing the climate control door assemblyfrom the front panel, maintenance and/or cleaning of the climate control unitmay be performed more easily in a workshop rather than in situ at the enclosure. Further, because the climate control door assemblyis removable, the climate control door assemblymay 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 bracketsto vertically separate the hingesand remove the climate control door assemblyfrom the front panel.

Turning to, the enclosuremay further include a cageinteriorly mounted to the front panelto block the climate control opening. Additionally, an interior portionof the climate control unitmay be mounted to the door panel. When the climate control door assemblyis in the closed configuration(shown in), the cagesurrounds the interior portion. Thus, in the closed configuration(shown in), the cagemay prevent damage to the interior portioncaused by movement of items within the enclosureand/or to prevent persons temporarily within the enclosure(e.g., loading and/or arranging refrigerated food) from tampering with the interior portion. Additionally, when the climate control door assemblyis in an open configuration, the cageprevents persons outside of the enclosurefrom tampering with items within the enclosure. Further, when the climate control door assemblyis in the open configuration, maintenance and/or cleaning may be performed on interior portionwithout a technician being inside the enclosure.

Looking again at, the enclosurefurther includes a second side walland a rear wallconnected to the bottom panel. Thus, in some embodiments, the enclosureis substantially box shaped. It should be understood that the enclosuremay have any three-dimensional form (e.g., cylindrical, conical, polyhedral, etc.). Additional elastomeric sealsare mounted to the front panelto sealably engage the door panelin the closed configuration(shown in). Further, the door paneldefines a first passageand a second passage, which are selectively blocked by the cover panel.

Referring to, the door paneladditionally defines a third passage. The first passageand the second passageare between the brackets. The third passageis located above the brackets. In some embodiments, the first passageand the second passageare substantially equal in size. In some embodiments, the first passageand the second passageare larger than the third passage.

Turning to, the exterior portionis operably and fluidly connected to the interior portionvia at least one conduit, which extends through the third passage. In some embodiments, the exterior portionincludes a condenser and/or a compressor of the climate control unit. In some embodiments, the interior portionincludes an evaporator and/or an expansion valve of the climate control unit. Additionally, in some embodiments, one or more of the conduitsis a drain. Further, in some embodiments, the conduitis insulated.

Referring to, in some embodiments, the interior portionis a cooling portion of the climate control unitand the exterior portionis a heating portion of the climate control unit. The cooling portion (i.e., interior portion) is the one or more components of the climate control unitthat provides cooling. The heating portion (i.e., exterior portion) is the one or more components of the climate control unitthat emits heat during operation of the climate control unit. The cooling portionmay be located on a first side of the door paneland the heating portionmay be located on a second side of the door panel. The first side of the door panelmay be located in and/or facing the interior of the enclosureand the second side of the door panelmay be located in and/or facing the exterior of the enclosure.

Remaining with, the latch assemblyincludes an upper hook, a handle, and a pull loop. The handleis located along an exterior sideof the door panel. Similarly, the pull loopis located along an interior sideof the door panel. The handleand the pull loopare operably connected to the upper hookto pivot the upper hookrelative to the door panel.

Turning to, the latch assemblyfurther includes a lower hook. The handle(shown in) and the pull loopare also operably connected to the lower hookto pivot the lower hookrelative to the door panel. When the climate control door assemblyis in the closed configuration(shown in), the handleis actuated to pivot the upper hookand the lower hooktoward the door panel. While pivoting toward the door panel, the upper hookand the lower hookengage and hook onto the front panel(shown in). Thus, the climate control door assemblyis tightly and sealably engaged with the front panelin the closed configuration. The upper hookand the lower hookmay be pivoted away from the door panelby pulling the pull loopand/or actuating the handle. Thus, the climate control door assemblymay be released from the front paneland the closed configurationfrom inside or outside of the enclosure(shown in).

illustrates a flow diagram depicting a methodto perform maintenance on the climate control unitofvia the climate control door assemblyof. The methodstarts at block, where the climate control door assemblyis unlocked from the front panel. More specifically, the handleand/or pull loopare actuated to release the upper hookand the lower hookfrom the front panel. The methodproceeds to block.

At block, the climate control door assemblyis opened to move from the closed configurationto the open configuration. The methodproceeds to block.

At block, maintenance is performed on the climate control unit. More specifically, a technician may clean, repair, inspect, do upkeep, etc. on the exterior portionand/or the interior portionwhile the climate control door assemblyis in the open configuration. The methodthen proceeds to block.

At block, the climate control door assemblyis closed to move from the open configurationto the closed configuration. The methodthen proceeds to block.

At block, the climate control door assemblyis locked to the front panel. More specifically, the handleis actuated to engage the upper hookand the lower hookto the front panel. The methodthen returns to block.

illustrate the enclosureto show the climate control door assemblyin the open configuration () and closed configuration ().

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.