Open-wall temperature-controlled environment

Abstract

The accessible cooling environment includes a rear wall, an opening opposite the rear wall, a roof panel, first and second sidewalls at least partially defining the opening, and an interior space at least partially defined by the rear wall, the roof panel, and the first and second sidewalls. A fan configured to circulate air through the interior space, an evaporator disposed within the interior space, and an air curtain assembly configured to form an air barrier adjacent to the opening. The air curtain assembly includes one or more deflectors for separating the air barrier into a first air curtain and a second air curtain. The first air curtain has a first temperature, and the second air curtain has a temperature lower than the first temperature.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to cooling environments, and more particularly to temperature-controlled cooling environments having open walls. [Background technology]

[0002] Refrigerated enclosures and refrigerated display cases are common storage solutions for produce and other products requiring refrigeration in supermarkets around the world. Some enclosures may be small-scale solutions that allow customers to open a refrigerated case door to access shelves of produce or reach into an open refrigerated display case. Other enclosures may be large-scale solutions that allow customers to enter an enclosed refrigerated environment or a large space to access refrigerated products. However, both small-scale and large-scale refrigeration systems face the challenge of keeping products cold while reducing heat transfer to the refrigerated space when either the door or entrance to the refrigerated space is open to ambient temperatures. Summary of the Invention

[0003] According to a first exemplary aspect of the present disclosure, the accessible cooling environment may include a rear wall, an opening opposite the rear wall, a roof, first and second sidewalls at least partially defining the opening, and an interior space at least partially defined by the rear wall, the roof, and the first and second sidewalls. A barrier may be disposed in the opening and extend between the first and second sidewalls, the barrier being movable between a closed position in which the barrier sealingly engages the floor and an open position in which the barrier is spaced apart from the floor. An evaporator may be disposed in the interior space and have an input and a coil. A control system may be connected to the evaporator. The control system may include at least one sensor coupled to the evaporator and configured to capture sensor data associated with a temperature of at least one of the input and the coil of the evaporator. The control system may include one or more processors and a memory communicatively coupled to the one or more processors and storing executable instructions that, when executed by the one or more processors, cause the one or more processors to receive sensor data captured by at least one sensor, analyze the sensor data to identify a state or condition associated with the evaporator, and send a heating or cooling signal to the evaporator based on the identified state or condition.

[0004] According to a second exemplary aspect of the present disclosure, the accessible cooling environment may include a rear wall, an opening opposite the rear wall, a roof panel, first and second side walls at least partially defining the opening, and an interior space at least partially defined by the rear wall, the roof panel, and the first and second side walls. A fan may be configured to circulate air through the interior space, and an evaporator may be disposed within the interior space. An air curtain assembly may be configured to form an air barrier adjacent to the opening. The air curtain assembly may include one or more deflectors to separate the air barrier into a first air curtain and a second air curtain. The first air curtain may have a first temperature, and the second air curtain may have a temperature lower than the first temperature.

[0005] In accordance with any one or more of the aforementioned first and second exemplary aspects, the accessible cooling environment may include any one or more of the following preferred forms:

[0006] In one preferred form, the accessible cooling environment may include an air curtain assembly.

[0007] In a preferred form, the air curtain assembly may include a fan and one or more deflectors.

[0008] In a preferred form, the fan and one or more deflectors may be configured to form an air barrier and direct the air barrier adjacent the opening.

[0009] In a preferred form, the air barrier may include a first air curtain at a first temperature and a second air curtain at a second temperature that is lower than the first temperature.

[0010] In another preferred form, one or more deflectors of the air curtain assembly may be positioned between the opening and the fan to separate the first and second air curtains.

[0011] In another preferred form, the air barrier may include a third air curtain having a lower temperature than the temperature of the second air curtain.

[0012] In a preferred form, the temperature of the first air curtain may be in the range of about 40 degrees Fahrenheit to about 50 degrees Fahrenheit.

[0013] In a preferred form, the temperature of the second air curtain may be in the range of about 33 degrees Fahrenheit to about 40 degrees Fahrenheit.

[0014] In a preferred form, the temperature of the third air curtain may be in the range of about 25°F to 33°F.

[0015] In a preferred form, the first air curtain may be adjacent to the opening, the third air curtain may be adjacent to the interior space, and the second air curtain may be positioned between the first and third air curtains.

[0016] In a preferred form, the at least one sensor may include a first sensor located at the input of the evaporator and a second sensor located on the coil of the evaporator.

[0017] In a preferred form, the one or more processors may be configured to compare sensor data at the evaporator input with sensor data in the evaporator coil.

[0018] In a preferred form, the one or more processors may be configured to compare sensor data of at least one sensor.

[0019] In a preferred form, the one or more processors may be configured to send a signal to the evaporator to increase the temperature of the evaporator and initiate a defrost cycle.

[0020] In a preferred form, a seal may be disposed between the barrier and at least one of the first and second side walls.

[0021] In a preferred form, the seal disposed between the barrier and at least one of the first and second side walls may be a brush seal.

[0022] In a preferred form, a seal may be disposed between the barrier and the floor when the barrier is in the closed position.

[0023] In a preferred form, the seal disposed between the barrier and the floor may be a valve seal.

[0024] In a preferred form, the barrier may be disposed in the opening and extend between the first and second side walls.

[0025] In a preferred form, the barrier may be movable from a closed position in which the barrier sealingly engages the floor, and an open position in which the barrier is spaced from the floor.

[0026] In a preferred form, a seal is disposed between the barrier and at least one of the first and second side walls.

[0027] In a preferred form, the seal disposed between the barrier and the floor may be a compressible seal.

[0028] In a preferred form, the barrier is capable of at least partially directing the air flow through the air barrier.

[0029] In a preferred form, the accessible cooling environment may include a defrosting system connected to the evaporator.

[0030] In a preferred form, the defrosting system may include at least one sensor coupled to the evaporator and configured to capture sensor data associated with a temperature of at least one of an input and a coil of the evaporator.

[0031] In a preferred embodiment, the at least one sensor includes a first sensor located at the input of the evaporator and a second sensor located inside the evaporator.

[0032] In a preferred form, the defrosting system may include one or more processors.

[0033] In a preferred form, the defrosting system may include a memory communicatively coupled to one or more processors and storing executable instructions that, when executed by the one or more processors, cause the one or more processors to receive sensor data captured by at least one sensor, analyze the sensor data to identify a condition or situation associated with the evaporator, and, based on the identified condition or situation, send a signal to the evaporator to heat or cool.

[0034] In a preferred form, an embedded heating element may be positioned adjacent the opening.

[0035] In a preferred form, the air curtain assembly may include at least one fan of a blower and an evaporator.

[0036] In a preferred form, the fan may include a blower located at least partially outside the interior space.

[0037] In a preferred form, the fan may include a plurality of evaporator fans. [Brief explanation of the drawings]

[0038] [Figure 1] FIG. 1 is a perspective view of an open wall cooler ("OWC") unit assembled in accordance with the teachings of the present disclosure. [Figure 2] 2 is a perspective view of the OWC unit of FIG. 1 showing the interior of the OWC unit obscuring the roof and side panels of the OWC unit. [Figure 2a] FIG. 10 is a perspective view of an alternative version of the OWC unit of the present disclosure, showing the interior of the OWC unit. [Figure 3] FIG. 2 is a cross-sectional side view of the OWC unit of FIG. 1 showing airflow through the OWC unit. [Figure 4] 2 is a perspective cross-sectional view of the OWC unit of FIG. 1 showing the air barrier formed by the first, second, and third air curtains. [Figure 4a] FIG. 2b is a perspective view of an alternative version of the OWC unit shown in FIG. 2a. [Figure 4b] FIG. 4b is a front right perspective view of the OWC unit shown in FIG. 4a. [Figure 4c] FIG. 4b is a cross-sectional side view of the OWC unit shown in FIG. 4a. [Figure 4d] FIG. 4b is a close-up view of a shelf support beam saddle of the height-adjustable shelf of the OWC unit of FIG. 4a. [Figure 4e] FIG. 4d is an enlarged partial view of a shelf support beam coupled to the shelf support beam saddle of FIG. 4d. [Figure 4f] FIG. 4b is a cross-sectional side view of the OWC unit of FIG. 4a showing the airflow through the OWC unit. [Figure 4g] FIG. 4b is a partial perspective view of the OWC unit shown in FIG. 4a with the right side wall removed. [Figure 4h] FIG. 4g is a perspective view of the honeycomb diffuser assembly. [Figure 4i] 4b is a partial perspective view of the OWC unit shown in FIG. 4a with components hidden to show a first exemplary diffuser. FIG. [Figure 4j] FIG. 4h is a front side perspective view of the OWC unit shown in FIG. 4h. [Figure 5] FIG. 2 is a partial rear perspective view of the OWC unit of FIG. 1 showing the control system. [Figure 6] FIG. 2 is a front view of the OWC unit of FIG. 1 showing the movable barrier in a closed position. [Figure 7] FIG. 2 is a front view of the OWC unit of FIG. 1 showing the movable barrier in an open position. [Figure 8] FIG. 7 is an enlarged view of the seal arrangement of the movable barrier in the closed position of FIG. 6. [Figure 9] FIG. 8 is a close-up view of the seal arrangement of the movable barrier in the open position of FIG. 7. [Figure 10] FIG. 2 is a schematic diagram of an example defrosting cycle of a control system for the OWC unit of FIG. 1 in accordance with the teachings of the present disclosure. [Figure 11] FIG. 2 is a perspective view of the OWC unit of FIG. 1 having multiple crates. [Figure 12] 1 is a perspective view of an exemplary layout of multiple OWC units assembled in accordance with the teachings of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0039] The present disclosure is directed to open-wall cooler ("OWC") units, also commonly referred to as accessible cooling environment units, open-wall temperature-controlled environments, and open-wall refrigeration units, which may be standalone units or configured in a layout containing multiple OWC units. OWC units are easy to build and can replace existing small- and large-scale refrigeration solutions by providing an energy-efficient refrigerated environment that provides a comfortable shopping experience for consumers.

[0040] 1 , OWC unit 100 is assembled in accordance with the teachings of the present disclosure. OWC unit 100 is a partially enclosed refrigerated storage space including a rear wall 104, an opening 108 opposite rear wall 104, a roof 112, and first and second side walls 116, 118 that partially define opening 108. An interior space 122 is defined by a ground or floor surface 126, rear wall 104, roof panel 112, and first and second side walls 116, 118. A barrier 130 also at least partially defines interior space 122 and is disposed in opening 108 between first side wall 116 and second side wall 118. Barrier 130 sealingly engages floor or ground 126 when in a closed position and is movable to an open position (as shown in FIG. 7 ) in which barrier 130 is spaced apart from floor or ground 126. As will be further explained below, barrier 130 provides OWC unit 100 with both a physical and a thermal barrier from the external environment.

[0041] The OWC unit 100 has a refrigeration system 134 that maintains the interior temperature and distributes refrigerated air throughout the interior space 122. The refrigeration system 134 includes a condenser 138 located on the roof 112, an evaporator 142 (shown in FIG. 2 ) located within the interior space 122, a blower 146 located on the roof 112, and an insulated duct 150 connecting the blower 146 to the interior space 122 of the OWC unit 100. A control system 154 is located on the roof 112, the interior space 122, or within the evaporator 142 and is coupled to the refrigeration system 134 to monitor, analyze, and control the refrigeration system 134 of the OWC unit 100. For example, the control system has a demand defrost cycle that keeps the evaporator 142 functioning at high efficiency. The control system 154 may be operated remotely or locally to operate the defrost cycle, change the temperature or fan speed, or control and / or operate other functions of the refrigeration system 134. The control system 154 may include one or more sensors coupled to the evaporator 142 or other areas within the interior space 122 of the OWC unit 100, one or more processors 155, and a memory 156 for storing executable instructions that enable automated operation of the defrost cycle and / or other features or programs of the refrigeration system 134. The refrigeration and control systems 134, 154 are located on (or near) the roof 112 of the OWC unit, although in other examples, the refrigeration and control systems 134, 154 may be located differently. For example, the blower 146, condenser 138, and control system 154 may be located outside the OWC unit 100, on the ground 126, or attached to any of the panels that define the OWC unit 100.

[0042] The roof 112, sidewalls 116, 118, and rear wall 104 of the OWC unit 100 of FIG. 1 are preferably constructed using connected insulated panels. The roof 112 may be constructed of one or more insulated panels joined together. Similarly, the first and second sidewalls 116, 118 each include a single insulated panel connected to both the roof 112 and the rear panel 104 via an insulating frame. The rear panel 104 may include one or more joined insulated panels attached to the roof and the first and second sidewalls 116, 118. In one example, the OWC unit 100 may have a length (i.e., extending between the first and second sidewalls 116, 118) of approximately 9 feet, a height (i.e., extending between the ground 126 and the roof 112), and a width (i.e., measured between the opening 108 and the rear wall 104) of approximately 5 feet. However, in other exemplary OWC units 100, these dimensions may vary. For example, the side walls 116, 118, and / or the rear wall 104 may include multiple connected insulated panels depending on the desired size and shape of the OWC unit 100. In other words, the OWC unit 100 may be customized. The panels may be connected to each other by a hybrid insulated frame, such as the hybrid frames disclosed in U.S. Patent No. 10,246,873, filed November 16, 2017, entitled "Insulated Structural Members for Insulated Panels and a Method of Making Same," U.S. Patent Application No. 16 / 663,910, filed October 25, 2019, entitled "Method of Manufacturing Hybrid Insulation Panel," and U.S. Patent Application No. 16 / 582,147, filed September 25, 2019, entitled "Hybrid Insulating Panel, Frame, and Enclosure," all of which are incorporated herein by reference. In other examples, the frame may be wood, metal, composite, foam, or a combination of materials.

[0043] Referring now to Figure 2, the partial OWC unit 100 of Figure 1 is shown. In Figure 2, a portion of an air curtain assembly 158 is shown, including one or more fans or blowers 162 of the evaporator 142, one or more deflectors 166, 167, 168, one or more perforated ceiling panels 172, and one or more rear panels 176, 178 disposed in the interior space 122 of the OWC unit 100. However, the air curtain assembly 158 also includes the blower 146 of Figure 1, which is hidden in Figure 2 for illustrative purposes. In this manner, air is circulated through the OWC unit 100 by the blower 146 and / or the fan 162 of the evaporator 142. The air curtain assembly 158 is configured to form and shape an air barrier 190 (Figures 3 and 4) adjacent the opening 108 of the OWC unit 100 to reduce air exchange across the opening 108 and to ensure that products disposed in the interior space 122 are bathed in a constant stream of cool air. The barrier 130 also serves to direct airflow from the opening 108 against the ground 126 and toward the rear wall 104 within the interior space 122 of the OWC unit 100. At the rear wall 104, the air is then directed into a duct 180 formed between the rear wall 104 and rear wall plates 176, 178, where the air may be recirculated through the evaporator 142 or through the blower 146 and returned into the OWC unit 100.

[0044] The first and second curved deflectors 166, 167 of the air curtain assembly 158 are curved, rotating vanes located adjacent to the roof 112 in the interior space 122 between the fan 162 of the evaporator 142 and the opening 108 of the unit 100. The two curved deflectors 166, 167 create a plenum that directs air into the first air curtain. The first curved deflector 166 forms one side of the plenum, and the second curved deflector 167 creates the other side of the plenum. The two curved deflectors 166, 167 create a sealed channel (like a funnel) through which air from the blower 146 flows into the first air curtain. The third deflector 168 is an angled plate that extends between the first sidewall 116 and the second sidewall 118 and is positioned between the perforated ceiling plate 172 and the roof 112. Deflectors 166, 167, 168 are positioned within the recirculated air flow path of OWC unit 100 to direct air at different temperatures along different paths, creating a vertical air barrier 190 at opening 108. Deflectors 166, 167, 168 may be metal deflectors, plastic honeycomb diffusers, or a combination of materials. As described in more detail below, deflectors 166, 167, 168 provide a temperature gradient at opening 108 of OWC unit 100 by directing air through multiple air curtains, each having a different temperature, limiting heat exchange at opening 108.

[0045] As shown in FIG. 2 , the first wall panel 176 is spaced apart from the ground 126 and from the second wall panel 178, thereby forming a first opening or slot 182 with the ground 126 and a second opening or slot 186 with the second wall panel 178. Air flows into the duct 180 through either the first or second opening 182, 186. The ceiling panel 172 allows air to enter the product space of the interior space 122 of the OWC unit 100. During operation, the air curtain assembly 158 limits air intrusion into the interior space 122 of the OWC unit 100, facilitating cooling of the product within the interior space 122. The fan 162 in the evaporator 142 and the blower 146 on the roof 112 direct the air toward the opening 108, and the deflectors 166, 167, and 168 divert the air, forming a vertical air barrier and evenly distributing cooled air throughout the interior space 122. The air from the air barrier 190 then circulates through the rear duct 180 and enters either the duct 150 and the blower 146 or the input of the evaporator 142 .

[0046] As shown in the second exemplary OWC unit 100 shown in FIG. 2a, the deflector 168 itself can have multiple surfaces angled relative to one another to further direct the airflow in a desired direction. For example, the deflector 168 can include inclined surfaces 168a, 168b that are angled lower toward the rear of the OWC unit 100 and higher toward the front of the OWC unit 100, with the inclined surfaces 168a, 168b meeting along an apex 168c, such as along the centerline of the OWC unit 100, and each of the inclined surfaces 168a, 168b depending downward from the apex 168c in a direction toward the respective sidewalls 116, 118 of the OWC unit 100. The apex is flat toward the rear of the OWC unit 100.

[0047] As shown in FIG. 3 , air is recirculated through OWC unit 100 according to an exemplary flow diagram. Vertical air barrier 190 is formed at opening 108 and includes first air curtain 192, second air curtain 194, and third air curtain 196. First, second, and third air curtains 192, 194, and 196 each have a different temperature within a specific temperature range, with third air curtain 196 having the lowest temperature of the three air curtains 192, 194, and 196. Refrigeration system 134 and air curtain assembly 158 work in conjunction to maintain the temperature of each air curtain 192, 194, and 196 within its respective temperature range. While the illustrated example of air barrier 190 includes three air curtains 192, 194, and 196, in other examples, air barrier 190 may include more or fewer than three air curtains 192, 194, and 196. Additionally, although the air barrier 190 is oriented to flow vertically across the opening 108, in other examples the air barrier may be oriented differently, such as horizontally or at a different angle, depending on the position of the air curtain assembly 158.

[0048] The first air curtain 192 is adjacent to the opening 108 and has the highest curtain temperature. For example, the temperature of the first air curtain 192 ranges from about 40°F to about 50°F, preferably about 45°F. The blower 146 passes air through the opening in the roof 112 into the interior space 122 and between the curved deflectors 166 and 167 to form the first air curtain 192. A honeycomb diffuser assembly 204, which may include one or more diffusers, is positioned at the bottom of the deflectors 166 and 167 and receives the first and second air curtains 192 and 194. The honeycomb assembly 204 conditions the air flow by reducing turbulence, creating a laminar air flow across the opening 108. The air flow flows vertically across the opening 108, thereby forming the first air curtain 192. The barrier 130 directs airflow from the first air curtain 192 into the interior 122 of the OWC unit 100 against the ground 126. The air then flows across the ground 126 toward the rear wall 104, through a first opening 182 in the rear wall panel 176, and into the rear duct 180. A portion of the air from the first curtain 192 is then routed through a duct 150 connected to the roof 112, to the blower 146, and recycled back through the OWC unit 100. The air forming the first air curtain 192 circulates along this path and does not enter the evaporator 142.

[0049] A second air curtain 194 of the air barrier 190 is formed between the first air curtain 192 and the third air curtain 196. Refrigerated air exiting the outlet fan 162 of the evaporator 142 enters the interior space 122 of the OWC unit 100, forming either the second air curtain 194 or the third air curtain 196. The angled and curved deflectors 168, 166, and 167 direct the refrigerated air through the space between the curved deflector 167 and the outer edge of the perforated ceiling plate 172, forming the second air curtain 194. In this manner, the curved deflectors 166, 167 separate the first and second air curtains 192, 194, which form the air barrier 190 adjacent the opening 108. The curved deflector 167 also shapes the air from the evaporator 142 and directs it toward the second air curtain 194. A portion of the air directed toward the second air curtain 194 separates to form a third air curtain 196. The air from the second air curtain 194 flows into the honeycomb assembly 204, across the opening 108, and into the interior space 122 of the OWC unit 100. A portion of the air from the second air curtain 194 reaches the ground, another portion flows across the lower portion of the interior space 122 (i.e., where the stored product is located) and enters the rear duct 180 through the first opening 182 in the rear wall panel 176, and another portion may flow through the optional second opening 186. The air from the second air curtain 194 flows vertically through the rear duct 180 and into the intake or input 214 of the evaporator 142, where it is recycled back through the OWC unit 100. The temperature of the second air curtain 194 ranges from about 30°F to about 40°F, and preferably is about 34°F.

[0050] The third air curtain 196 is adjacent to the second air curtain 194 and the interior space 122 of the OWC unit 100. The third air curtain 196 has a temperature ranging from about 25°F to about 35°F, and preferably has a temperature of about 32°F. As such, the third air curtain 196 has the lowest temperature of the air barrier 190. Similar to the second air curtain 194, cooled air exiting the evaporator 142 is directed toward the opening 108 of the OWC unit 100. The third air curtain 196 flows partially across the opening 108 into the upper portion of the interior space 122 and through the second opening 186 formed by the rear wall panels 176, 178. The air then flows into the input 214 of the evaporator 142 and is recycled back through the OWC unit 100. A portion of the air from the first air curtain 192, as well as the second air curtain 194 and the third air curtain 196, may be recirculated through the blower 146 and into the interior space 122 during normal operation.

[0051] 4a-4f, the OWC unit 100 may include a height-adjustable shelf 500. The height-adjustable shelf 500 may be a wire shelf. A plurality of vertically spaced height adjustment holes 502 may be provided along the sidewalls 116, 118, which may be connected to the sidewalls 116, 118 via bolts on rail saddles 506. As shown in FIGS. 4d and 4e, to facilitate adjustability, each of the shelf support beams 504 may be seated on a pair of rail saddles 506, each defined by a floor, an end wall from which pegs or dowels protrude, and a pair of spaced-apart sidewall members, the spaced-apart sidewall members and the floor defining a U-shaped channel to receive the shelf support beam 504. The height-adjustable shelf 500 advantageously provides a support surface for eye-level retail display of merchandise within the OWC unit, above one or more stacks of palletized products.

[0052] The height-adjustable shelf 500 is provided with wing-like curved light / air deflectors 508 that help protect and direct light from light bulbs, such as elongated LED light bulbs 509, which are in electrical communication with the power source for the OWC unit 100. The light 509 may be a variety of light sources, such as electroluminescent tape, phosphor crystals, organic light-emitting diodes (OLEDs), fiberglass tubes, solar cells or arrays, neon or other gas-filled lights, or other lighting materials. In addition to reflecting light toward the area of ​​the OWC unit 100 and the palletized goods below the height-adjustable shelf 500, the wing-like curved light / air deflectors 508 also serve to direct cooled air from the second and third air curtains 194, 196 toward the bottom and front of the palletized products within the OWC unit 100, as can be seen with reference to FIG. 4f.

[0053] Referring to Figures 4g-4j, a honeycomb diffuser assembly 204 is assembled in accordance with the teachings of the present disclosure. The honeycomb diffuser assembly 204 includes a variable-height honeycomb diffuser 510 and a non-variable-height diffuser 514. In the illustrated example, the variable-height honeycomb diffuser 510 is used in conjunction with one or more non-variable-height diffusers or diffuser sections 514, as shown in Figure 4h. However, in other examples, the honeycomb diffuser assembly 204 may include one or more variable-height diffusers or one or more non-variable-height diffusers. As used herein, "variable height" refers to one or more different heights measured on the Z coordinate axis, as shown in Figures 4h-4j. The height of the diffuser 510 may vary along the length of the diffuser 510 extending on the X coordinate axis, or, in other words, between the first sidewall 116 and the second sidewall 118 of the OWC unit 100. The diffuser 510 may be sloped, stepped, corrugated, ridged, or otherwise non-planar about one or more of its top and bottom surfaces. However, in another example, the height of the diffuser may alternatively or additionally vary along the width of the diffuser 510, which extends in the Y coordinate axis. Furthermore, as used herein, "non-variable height" refers to a uniform height measured on the Z coordinate axis, such that the diffuser has uniform, flat, or horizontal top and / or bottom surfaces.

[0054] As shown in FIG. 4g, the honeycomb diffuser assembly 204 is positioned immediately aft of the bottoms 522, 524 of the first and second deflectors 166, 167 such that the inlets 518, 520 of each diffuser 510, 514 are positioned proximal to the first and second deflectors 166, 167, respectively. As shown in FIGS. 4c and 4g, the bottoms 522, 524 of each deflector are offset relative to the honeycomb assembly 204. In the particular example of FIG. 4g, the non-variable height diffuser 514 is spaced apart from the bottom 522 of the first deflector 166 and adjacent to the bottom 524 of the second deflector 167. As shown in FIGS. 4i and 4j, the variable height diffuser 510 is spaced apart from the bottom 524 of the second deflector 167. When so configured, the deflectors 166, 167, 168 direct air through channels formed between the first deflector 166 and the second deflector 167 to the inlets 518, 520 of the diffusers 510, 514. The diffusers 510, 514 shape the airflow, causing the air to flow through multiple channels 526 in the diffusers 510, 514.

[0055] As shown more clearly in Figure 4i, the channels 526 of the variable-height diffuser 510 have square or rectangular openings separated or defined by walls. As shown in Figure 4h, the channels 526 are the same or similar in both the diffuser 510 and the diffuser 514. However, in other examples, the channels 526 may be circular, octagonal, or other polygonal with walls separating each channel of varying thickness.

[0056] In Figure 4h, the variable and non-variable height diffusers 510, 514 are shown from a perspective looking out from the inside of the OWC unit 100. Generally speaking, the entrance or top surface 518 of the variable height diffuser 510 is non-planar relative to the planar entrance 520 of the non-variable height diffuser 514. However, on the right side of the assembly 204 (i.e., adjacent the first sidewall 116 of the OWC unit 100 in Figure 4g), the variable and non-variable height diffusers 510, 514 initially extend along the X axis at the same height h1 measured on the Z coordinate axis. However, in other examples, the heights of the first and second diffusers 510, 514 may not coincide or be aligned, or they may coincide on the left side (i.e., adjacent the second sidewall 118 of the OWC unit 100) or between the right and left ends of the diffuser assembly 204. The outlet 528 or bottom surface of the variable-height diffuser 510 is planar and, in the illustrated example, is coplanar with the outlet 530 ( FIG. 4g ) or bottom surface of the non-variable-height diffuser 514. However, in other examples, the outlets 528, 530 of one or more of the diffusers 510, 514 may be non-planar, such as, for example, corrugated and / or staggered. In yet additional examples, the variable and non-variable-height diffusers 510, 514 may be spaced apart from one another in the Y coordinate direction (into the page in FIG. 4h ), or they may be staggered relative to the Z coordinate axis. The diffusers 510, 514 may be separate components, or the diffusers 510, 514 may be fixedly attached to form a single component.

[0057] By providing the honeycomb diffuser 510 with multiple heights and profiles across the length of the honeycomb (i.e., across the width of the OWC unit 100 and / or between the first sidewall 116 and the second sidewall 118), it can be seen that the honeycomb diffuser 510 is better able to attenuate the highly variable air velocities imparted by the fans 142a, 142b, 142c, 142d, and 142e of the evaporator 142 (FIG. 4g). High air velocities on the order of 800 feet per minute are observed at the center of the air curtain, while significantly lower air velocities (on the order of about 100 to about 200 feet per minute) are observed at the far ends of the air curtain. The diffuser assembly 204 is designed to maximize air distribution across the openings 108 of the OWC unit 100 based on the airflow characteristics within the OWC unit 100. While the variable-height honeycomb diffuser 510 is shown (e.g., in Figures 4h-4j) as having a first region 510a with a first height h1, a second region 510b with a second height h2 that is shorter than the first region 510a, and a tapered third region 510c, it is recognized that the topography of the variable-height honeycomb diffuser 510 is not limited to that shown. Rather, the topography can be selected to provide optimal airflow uniformity within the OWC unit 100 to compensate for variations in evaporator fan output and achieve desired airflow velocity and / or pressure. Improving air velocity through the honeycomb structure of the diffuser 204 facilitates maintaining lower air and product temperatures, particularly near the floor, resulting in greater energy efficiency.

[0058] 1 and 5 show the control system 154 in more detail. The control system 154 is disposed on the roof 112 (hidden in FIG. 5 ) or on the evaporator 142 of the OWC unit 100 and is coupled to control various functions of the air curtain assembly 158 and / or the refrigeration system 134. For example, the control system 154 may operate a defrost cycle and may include at least one sensor coupled to the evaporator 142 and configured to capture sensor data associated with the temperature at the input 214 and / or within the evaporator 142, such as the coils of the evaporator 142. The control system 154 includes one or more processors 155 and a memory 156 communicatively coupled to the one or more processors 155 and storing executable instructions for operating the refrigeration system 134. The executable instructions cause the one or more processors 155 to receive sensor data captured by the one or more sensors, analyze the sensor data to identify a condition or condition associated with the evaporator 142, and send a heating or cooling signal to the evaporator 142 based on the identified condition or condition.

[0059] 5, the control system 154 includes a first sensor 211, a second sensor 212, a third sensor 213, and a conduit 216, or temperature wires, connecting the first, second, and third sensors 211, 212, and 213 to the control system 154. The temperature wire 216 runs through the front (i.e., outlet side) of the evaporator 142 and through the back (i.e., inlet side) of the evaporator 142. The first sensor 211 is in the return airflow before entering the coils at the input 214 of the evaporator 142, the second sensor 212 is located on the suction line 215 connecting the evaporator 142 to the condenser 138, and the third sensor 213 is located inside the evaporator 142 between the coils of the evaporator 142 (i.e., where the ice last disappears). When so configured, the three temperature sensors 211, 212, 213 relay information about the temperature at various locations on or near the evaporator 142 to the control system 154 to determine exactly when and for how long a defrosting cycle should be performed, as well as monitor the evaporator 142 during defrosting and cooling cycles.

[0060] Also shown in FIG. 5 is a backer 217 of the OWC unit 100. The backer 217 provides structural support to the OWC unit 100 and helps direct airflow through the rear duct 180. The OWC unit 100 may include multiple backers 217 spaced along the rear wall 104 of the OWC unit 100. The backers 217 may be positioned to direct airflow from the rear duct 180 (via duct 150) to the blower 146, as shown in FIG. 2. Together with the rear wall 104 and wall plates 176, 178, the backers 217 may define another plenum formed within the rear duct 180 to distribute air to the input 214 of the evaporator 142. One or more of the backers 217 may be a "Z" backer having a Z cross-section. The backers 217 may extend partially or entirely along the height of the OWC unit 100.

[0061] Referring now to FIGS. 6-9, the OWC unit 100 is shown with the barrier 130 in a closed position ( FIGS. 6 and 8 ) and an open position ( FIGS. 7 and 9 ). The barrier 130 is a movable plate that helps protect the products stored in the OWC unit 100 while continuing to allow air to circulate through the interior space 122 of the OWC unit 100. In FIG. 6 , the barrier 130 sealingly engages the floor 126, limiting heat exchange across the opening 108. As cooled air flows from the air barrier 190 toward the ground 126, the barrier 130 keeps the cooled air within the interior space 122. When the barrier 130 is in the closed position, the opening 108 in the OWC unit 100 is large enough for customers to comfortably reach the OWC unit 100 and access the products stored in the interior space 122. In FIG. 8 , the barrier 130 is raised to the open position, allowing the OWC unit 100 to be restocked with items requiring refrigeration. In particular, the barrier 130 may be raised to a height that allows a forklift to enter the OWC unit 100 to deliver or remove a pallet of items from the OWC unit 100 .

[0062] A first seal 218 is disposed along the bottom edge 222 of the barrier 130, and a second seal 226 is disposed at the first and second side edges 230, 234 of the barrier 130. FIG. 8 shows an enlarged view of the first seal 218 and the second seal 226 at the bottom edge 222 and second side edge 234 of the barrier 130 when the barrier 130 is in the closed position. The first seal 218 is a durable seal, such as a valve seal, having a width substantially similar to the width of the barrier 130 and a length extending along the bottom edge 222 of the barrier 130. When the barrier 130 is in the closed position, the seal 218 is compressed under the weight of the barrier 130 and seals against the floor 126. As shown in FIGS. 7 and 9, when the barrier 130 is in the open position, the seal 218 is in an uncompressed configuration. Seal 218 may be flexible to accommodate any uneven surfaces in floor 126 and configured to create a seal even when light debris is placed on ground 126 and within opening 108. Seal 218 is also durable for repeated use in low temperature environments. Seal 218 may be a spherical seal, brush seal, or other suitable seal, which may be made of foam, vinyl, and rubber and may be of either a filled or solid configuration.

[0063] The second seals 226 are disposed between the first and second side edges 230, 234 of the barrier 130, respectively, and the first and second side walls 116, 118. The second seals 226 allow movement of the barrier 130 between the open and closed positions while sufficiently sealing a joint 238 between the first and second side walls 116, 118 and the barrier 130, thereby limiting the escape of cold air from the OWC unit 100 at the joint 238. The joint 238 (i.e., where the barrier 130 is coupled to the first and second side walls 116, 118) may be a slide rail, pulley, or other mechanical device that slidably connects the barrier 130 to the first and second side walls 116, 118. The joint 238 allows an operator or an automatic pulley or other mechanical system to lift the barrier 130 from the closed position to the open position. The barrier 130 may remain in the open position by engaging a locking mechanism or other device.

[0064] Returning briefly to FIG. 6 , optional heating device 242 is shown in dashed lines. Heating device 242 is embedded in OWC unit 100 such that device 242 is positioned along the bottom of opening header 243 between first sidewall 116 and second sidewall 118, and along a stainless steel three-sided guard that protects the outer edges of first and second sidewalls 116, 118 and opening header 243. Heating device 242 is configured to raise the temperature of surfaces surrounding opening 108 above the dew point range. Heating device 242 may include heated wires that extend around opening 108 in OWC unit 100, particularly where heat is removed from surfaces around opening 108 by refrigeration system 134. However, in other examples, the heating wire may extend partially around the opening 108, may be located in a target area within a segment around the opening 108, may be located only against the edges of the sidewalls 116, 118, or may be located only against the door header of the roof panel 112. In one example, the heating device 242 includes a 10 watt / line foot self-regulating heater such as Chromalox® CPR ​​heat trace, and may be controlled by a creep action thermostat such as a PEPI® creep action thermostat that is also embedded behind the stainless steel three-sided jamb guard trim of the opening 108. The heating device 242 may be controlled locally or remotely and may be operated separately from the control system 154 and separately from operating the barrier 130.

[0065] 10 illustrates an exemplary flow diagram for operating the control system 154 of the OWC unit 100. In a first block 310, sensor data is continuously (or periodically) collected by at least one sensor coupled to the evaporator 142. For example, the sensor may collect temperature data at the input 214 and the coil of the evaporator 142. In a second block 320, the one or more processors 155 receive the sensor data captured by the sensor. In a third block 330, the one or more processors 155 analyze the sensor data and compare the sensor data with instructions stored in the memory 156. For example, the temperature captured by the at least one sensor may be compared to a temperature associated with a state or condition of the evaporator 142 stored in the memory 156. The captured temperature may be compared to a threshold temperature stored in the memory 156. In another example, the processor 155 measures the difference between the temperature of the input 214 of the evaporator 142 and the coil of the evaporator 142. If the measured temperature or temperature difference meets or exceeds the stored threshold, the state or condition associated with the evaporator 142 at that threshold temperature is identified and assigned in block 340. Based on that identification, in block 350, the control system 154 sends a signal to the evaporator 142 to initiate defrosting.

[0066] For defrosting operations, the control system 154 operates according to the flow chart of FIG. 10 to limit ice formation on the evaporator coil. Ice formation on the evaporator 142 can reduce the operating efficiency of the evaporator 142 and reduce its ability to remove heat from the air. The defrosting cycle of the disclosed control system 154 periodically adds heat to the evaporator 142 and removes ice from the coil to maintain the lowest possible average temperature within the OWC unit 100. The defrosting function is based on the temperature difference between the evaporator coil and the air entering the evaporator 142. The defrosting function of the control system 154 measures the temperature difference by monitoring first, second, and third temperature sensors 211, 212, and 213. The temperature at various locations near or on the evaporator 142 may be monitored over a period of time. If the temperature difference between the evaporator coil and the input 214 exceeds a temperature difference threshold stored in the memory 156, a defrost cycle is initiated by sending a signal to the evaporator 142 to increase the temperature of the coil assembly within the evaporator 142. The defrost function also monitors the evaporator 142 coil, which is where ice last disappears. If this temperature reaches a certain threshold, the defrost cycle may stop because the data indicates that the evaporator 142 is ice-free. Furthermore, the temperature obtained at the suction line 215 connecting the evaporator 142 and the condenser 138 may indicate ice formation on the evaporator 142. For example, during normal operation, heat is transferred to the refrigerant, and that heat is read by the second temperature sensor 212. If ice forms on the evaporator 142 coil, the second temperature sensor 212 will not sense any heat being transferred to the refrigerant because that heat is blocked by the ice buildup. In this case, the temperature sensor 212 helps determine when to initiate a defrost cycle. Other sensor configurations and algorithms for performing defrost cycles are possible. On-demand defrost cycles reduce the number of daily defrosts typical of a refrigeration system, thereby saving energy. Defrost cycles are also performed as needed. Control system 154 may operate other functions involving other sensors and sensor data. In other examples, control system 154 may operate pressure sensors, humidity sensors, and auxiliary temperature sensors.

[0067] 11 illustrates an OWC unit 100 having multiple stacked crates or pallets 400 assembled in accordance with the teachings of the present disclosure. In FIG. 11, a facade 404 extends from the roof 112 to conceal the refrigeration and control systems 134, 154 and may provide an opportunity for design or advertising display.

[0068] Figure 12 illustrates an exemplary OWC unit layout 500 including a plurality of OWC units 100 assembled in accordance with the teachings of the present disclosure. As shown in Figure 12, the plurality of OWC units 100 are assembled in two parallel rows in a back-to-back configuration (i.e., the rear wall 104 of one OWC unit 100 is adjacent to or abutting the rear wall 104 of another OWC unit 100), with an OWC unit 100 located at each end of the row. However, other layouts and orientations are possible.

[0069] The OWC unit 100 of the present disclosure provides an energy-efficient solution for storing and cooling products. First, the air curtain design and barrier 130 of the OWC unit 100 work together to limit heat exchange across the opening 108, thereby requiring less energy to maintain a lower temperature. The circulation provided by the air curtain assembly also more evenly distributes the cooling air within the interior 122 of the OWC unit 100. As a result, products may be continuously surrounded by refrigerated air, and in the case of produce, even cooling makes them less susceptible to localized damage from frost. For example, the air curtains 192, 194, and 196 of the present disclosure can be directed and deflected to flow through different sections or spaces of the interior space 122 of the OWC unit 100. For example, the first air curtain 192 can flow underneath the product near the ground 127, the second curtain 194 can flow over the center of the stored product, and the third air curtain 196 can flow across the top of the product.

[0070] Second, the refrigeration system 134 and control system 154 also help reduce energy consumption and keep the cost of operating the OWC unit low. The control system 154 may be programmed to perform on-demand defrost cycles to run the evaporator 142 more efficiently, thereby extending the operating life of the refrigeration system 134. In addition to energy efficiency, the refrigeration system 134 required for each OWC unit 100 is relatively small compared to existing cooling solutions. For example, each unit includes a compact condenser 138 that reduces noise and takes up less space.

[0071] The OWC unit 100 of the present disclosure also provides an accessible, low-maintenance refrigerated storage solution. The movable barrier 130 facilitates product stocking and refilling and allows for easy cleanup by simply moving the barrier 130 to the open position. In the open position, workers can access the product crates with a forklift and easily clean the ground surrounding the crates. The interior space 122 is simple, allowing for easy stacking of product crates for customer access. In other embodiments, the OWC unit 100 may include built-in or roller-mounted shelving. When the barrier 130 is in the closed position, the opening 108 allows customers to comfortably reach the interior 122 of the OWC unit 100 and grab products stored within the OWC unit 100. This solution provides a more comfortable shopping experience because customers do not have to fully enter the refrigerated compartment to access products.

[0072] OWC unit 100 is also easy to assemble and may be scaled up or down to meet customer needs. For example, a supermarket owner is not limited to a single location for installing OWC unit 100. Due to its small footprint and modular construction, OWC unit 100 can be moved to another location fairly easily. Furthermore, OWC unit 100 may be remotely managed to perform some functions, such as moving barrier 130, monitoring refrigeration system 134, and operating control system 154.

[0073] Preferred embodiments of the present invention are described herein, including the best mode or modes known to the inventors for carrying out the invention. While numerous examples are shown and described herein, those skilled in the art will readily understand that the details of the various embodiments are not necessarily mutually exclusive. Rather, one of ordinary skill in the art, after reading the teachings herein, will be able to combine one or more features of one embodiment with one or more features of the remaining embodiments. It should further be understood that the illustrated embodiments are merely exemplary and should not be construed as limiting the scope of the invention. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better clarify exemplary embodiments or aspects of embodiments of the invention, and does not limit the scope of the invention. No language in the specification should be construed as indicating any element not claimed as essential to the practice of the invention.

Claims

1. an accessible cooling environment, a rear wall, an opening opposite the rear wall, a roof, first and second side walls at least partially defining the opening, and an interior space at least partially defined by the rear wall, the roof, and the first and second side walls; a barrier disposed in the opening and extending between the first and second side walls, the barrier being slidably movable between a closed position in which the barrier sealingly engages the floor and an open position in which the barrier is spaced upwardly from the floor, wherein in the closed position the barrier sealingly engages the floor along first seals, the first seal having a width substantially the same as a width of the barrier and a length extending along a bottom edge of the barrier, and the barrier sealingly engages the first and second side walls respectively along second seals, one second seal along a first side edge of the barrier and the other second seal along a second side edge of the barrier, the barrier being slidably connected to the first and second side walls; an evaporator disposed in the interior space and having an input and a coil; a control system connected to the evaporator, the control system comprising: at least one sensor coupled to the evaporator and configured to capture sensor data associated with a temperature of at least one of the input and the coil of the evaporator; one or more processors; communicatively coupled to the one or more processors, and when executed by the one or more processors, causing the one or more processors to: receiving the sensor data captured by the at least one sensor; analyzing the sensor data to identify a state or condition associated with the evaporator; and a memory storing executable instructions that cause the evaporator to send a signal to heat or cool based on the identified condition or state.

2. 10. The accessible cooling environment of claim 1, further comprising an air curtain assembly including a fan and one or more deflectors, the fan and the one or more deflectors configured to form an air barrier and direct the air barrier adjacent the opening, the air barrier including a first air curtain at a first temperature and a second air curtain at a second temperature lower than the first temperature.

3. The accessible cooling environment of claim 2 , wherein the one or more deflectors of the air curtain assembly are disposed between the opening and the fan to separate the first and second air curtains.

4. The accessible cooling environment of claim 2 , wherein the air barrier includes a third air curtain having a temperature lower than the temperature of the second air curtain.

5. 5. The accessible cooling environment of claim 4, wherein the temperature of the first air curtain is in a range of 40 degrees Fahrenheit to 50 degrees Fahrenheit, the temperature of the second air curtain is in a range of 33 degrees Fahrenheit to 40 degrees Fahrenheit, and the temperature of the third air curtain is in a range of 25 degrees Fahrenheit to 35 degrees Fahrenheit.

6. 3. The accessible cooling environment of claim 2, further comprising a diffuser having a variable height and positioned closer to the front of the opening than the one or more deflectors, the diffuser including a plurality of channels forming a honeycomb structure.

7. The accessible cooling environment of claim 6 , wherein the height of the diffuser varies over a length extending between the first and second side walls.

8. The accessible cooling environment of claim 6 further comprising a second diffuser adjacent to the diffuser.

9. The accessible cooling environment of claim 1 , wherein the at least one sensor includes a first sensor disposed at the input of the evaporator and a second sensor disposed inside the evaporator.

10. 8. The accessible cooling environment of claim 7, wherein the one or more processors are configured to compare sensor data of the at least one sensor and send a signal to the evaporator to increase the temperature of the evaporator and initiate a defrosting cycle.

11. The accessible cooling environment of claim 1 , further comprising a seal disposed between the barrier and the floor when the barrier is in the closed position.

12. The accessible cooling environment of claim 1 , further comprising a shelf disposed in the interior space and a curved air deflector adjacent an outer edge of the shelf.

13. The accessible cooling environment of claim 12 , further comprising a light coupled to the shelf and positioned adjacent an inner surface of the curved air deflector.

14. an accessible cooling environment, a rear wall, an opening opposite the rear wall, a roof panel, first and second side walls at least partially defining the opening, and an interior space at least partially defined by the rear wall, the roof panel, and the first and second side walls; at least one fan configured to circulate air through the interior space; an evaporator disposed within the interior space; an air curtain assembly configured to form an air barrier adjacent the opening, the air curtain assembly including one or more deflectors to separate the air barrier into a first air curtain and a second air curtain; a barrier disposed in the opening and extending between the first and second side walls, the barrier being slidably movable between a closed position in which the barrier sealingly engages the floor and an open position in which the barrier is spaced upwardly from the floor, wherein in the closed position the barrier sealingly engages the floor along first seals, the first seal having a width substantially the same as a width of the barrier and a length extending along a bottom edge of the barrier, and the barrier sealingly engages the first and second side walls respectively along second seals, one second seal along a first side edge of the barrier and the other second seal along a second side edge of the barrier, the barrier being slidably connected to the first and second side walls; An accessible cooling environment comprising: a diffuser having a plurality of channels and a variable height when the diffuser extends between the first and second sidewalls.

15. 15. The accessible cooling environment of claim 14, wherein the first air curtain has a first temperature and the second air curtain has a temperature that is lower than the first temperature.

16. 15. The accessible cooling environment of claim 14, wherein the air barrier includes a third air curtain having a temperature lower than that of the second air curtain.

17. 17. The accessible cooling environment of claim 16, wherein the third air curtain is positioned adjacent to the interior space, the first air curtain is positioned adjacent to the opening, and the second air curtain is positioned between the first air curtain and the third air curtain.

18. The accessible cooling environment of claim 14 , further comprising a shelf disposed in the interior space and a curved air deflector adjacent an outer edge of the shelf.

19. 20. The accessible cooling environment of claim 18, further comprising a light coupled to the shelf and positioned adjacent an inner surface of the curved air deflector.

20. a defrosting system connected to the evaporator, the defrosting system comprising: at least one sensor coupled to the evaporator and configured to capture sensor data associated with a temperature of at least one of an input and a coil of the evaporator; one or more processors; communicatively coupled to the one or more processors, and when executed by the one or more processors, causing the one or more processors to: receiving sensor data captured by the at least one sensor; analyzing the sensor data to identify a state or condition associated with the evaporator; 15. The accessible cooling environment of claim 14, comprising: a memory storing executable instructions that cause the evaporator to send a signal to heat or cool based on the identified state or condition.

21. 21. The accessible cooling environment of claim 20, wherein the at least one sensor includes a first sensor disposed at the input of the evaporator and a second sensor disposed inside the evaporator.

22. 21. The accessible cooling environment of claim 20, wherein the one or more processors are configured to compare sensor data of the at least one sensor and send a signal to the evaporator to increase the temperature of the evaporator and initiate a defrosting cycle.

23. The accessible cooling environment of claim 3 , wherein the fan comprises a blower disposed at least partially outside the interior space.

24. The accessible cooling environment of claim 23 , wherein the fan comprises a plurality of fans on the evaporator.

25. The accessible cooling environment of claim 2 , wherein the air curtain assembly includes a blower and at least one fan of the evaporator.

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