Refrigerated appliance with chilled catch pans

Abstract

A refrigerated appliance can include a refrigeration system, a cabinet including: a first refrigerated portion defining a pan storage cavity configured to receive at least one food pan; a second refrigerated portion positioned below the first refrigerated portion and including; an insulated enclosure defining an interior surface and a base cavity; and a worktop cavity defined in a worktop defined by the cabinet, the worktop defining at least in part the second refrigerated portion, the worktop cavity configured to receive a catch pan, the catch pan configured to be cooled by air inside the insulated enclosure. A method of using a refrigerated appliance can include inserting a catch pan into a rail comprising a worktop portion and a rail portion, the catch pan received within a worktop cavity defined within the worktop portion; and cooling the catch pan through cooling of an interior cavity of the appliance.

Description

REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 762,630, filed Feb. 24, 2025, which is hereby specifically incorporated by reference herein in its entirety. This application also specifically incorporates by reference herein in its entirety U.S. application Ser. No. 17 / 889,246, filed on Aug. 16, 2022, and entitled REFRIGERATED APPLIANCE WITH DUCTED AIR FLOW; and U.S. application Ser. No. 17 / 889,249, filed on Aug. 16, 2022, and entitled REFRIGERATED APPLIANCE WITH AUTOMATICALLY ADJUSTABLE SETPOINT.TECHNICAL FIELDField of Use

[0002] This disclosure relates to refrigerated appliances. More specifically, this disclosure relates to refrigerated appliances with a refrigerated rail and refrigerated lower cabinet and refrigerated catch pans cooled by air circulated through an air plenum system.Related Art

[0003] A refrigerated appliance comprising an open, refrigerated rail is common and useful in a kitchen. Able to store at refrigerated temperatures a large variety of food ingredients used in food preparation such as the making of pizzas and sandwiches, such appliances can significantly improve user convenience and efficiency. The food ingredients stored in the open rail are not uncommonly placed on prepared food dishes (e.g., a pizza) in such a way that some of the ingredients fall into an area of the counter under and / or around the prepared dishes. Even where a structure for collecting such food product is present, the structure is not typically able to maintain the food product at sufficiently cool temperatures, meaning the collected food may not be able to be reused, or the structure is expensive, cumbersome, and / or prone to failure.SUMMARY

[0004] It is to be understood that this summary is not an extensive overview of the disclosure. This summary is exemplary and not restrictive, and it is intended to neither identify key or critical elements of the disclosure nor delineate the scope thereof. The sole purpose of this summary is to explain and exemplify certain concepts of the disclosure as an introduction to the following complete and extensive detailed description.

[0005] In one aspect, disclosed is a refrigerated appliance comprising: a refrigeration system, an evaporating unit thereof configured to supply air to an air plenum system of the appliance, the air plenum system configured to cool the appliance; a cabinet defining the air plenum system, the cabinet comprising: a first refrigerated portion defining a pan storage cavity configured to receive at least one food pan; a second refrigerated portion positioned below the first refrigerated portion and comprising; an insulated enclosure defining an interior surface and a base cavity configured to receive stored product; a duct received within the insulated enclosure and defining, at least in part, a communication air cavity, the communication air cavity being in fluid communication with each of the pan storage cavity and a return air cavity, the return air cavity being in fluid communication with the evaporating unit; and a worktop cavity defined in a worktop defined by the cabinet, the worktop defining at least in part the second refrigerated portion, the worktop cavity configured to receive a catch pan, the catch pan configured to be cooled by air inside the insulated enclosure.

[0006] In a further aspect, disclosed is a method of using a refrigerated appliance comprising: inserting a catch pan into a rail comprising a worktop portion and a rail portion, the catch pan received within a worktop cavity defined within the worktop portion; and cooling the catch pan through cooling of an interior cavity of the appliance.

[0007] Various implementations described in the present disclosure may comprise additional systems, methods, features, and advantages, which may not necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims. The features and advantages of such implementations may be realized and obtained by means of the systems, methods, features particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims or may be learned by the practice of such exemplary implementations as set forth hereinafter.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the disclosure and together with the description, serve to explain various principles of the disclosure. The drawings are not necessarily drawn to scale. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity.

[0009] FIG. 1 is a top right perspective view of a two-section refrigerated preparation table appliance with a raised rail in accordance with one aspect of the current disclosure.

[0010] FIG. 2 is a top front left perspective view of a lower left portion of the appliance of FIG. 1.

[0011] FIG. 3 is a partially exploded rear perspective view of the lower left portion of the appliance of FIG. 1 showing various access panels removed and offset from the appliance.

[0012] FIG. 4A is a top front perspective view of the appliance of FIG. 1.

[0013] FIG. 4B is a detail top front perspective view of the appliance of FIG. 1.

[0014] FIG. 4C is a detail top front perspective view of a right end of a worktop portion of the appliance of FIG. 1 with a worktop support in place.

[0015] FIG. 4D is a detail top front perspective view of a right end of the worktop portion of the appliance of FIG. 1 with a portion of the worktop support removed and showing a catch pan received within the worktop portion.

[0016] FIG. 4E is a detail top front perspective view of a right end of the worktop portion of the appliance of FIG. 1 with a portion of the worktop support removed and showing a cover received within the worktop portion.

[0017] FIG. 5 is a sectional view of the appliance of FIG. 1 taken along line 5-5 of FIG. 1.

[0018] FIG. 6A is a schematic view of a refrigeration system of the appliance of FIG. 1.

[0019] FIG. 6B is a perspective view of the refrigeration system of FIG. 6A.

[0020] FIG. 7 is a schematic view of an airflow circuit of the appliance of FIG. 1.

[0021] FIG. 8 is a detail front perspective view of a left side of a cabinet base of the appliance of FIG. 1 showing a primary controller configured to control an air temperature of the rail and a secondary controller configured to control an air temperature of an interior cavity of the cabinet.

[0022] FIG. 9A is a sectional view of the appliance of FIG. 1 taken along line 9A-9A of FIG. 5.

[0023] FIG. 9B is a detail sectional view of the appliance of FIG. 1 taken along line 9B-9B of FIG. 9A in accordance with another aspect of the current disclosure and showing only geometry in the cut plane.

[0024] FIG. 10 is a bottom perspective view of a cabinet fan assembly of the appliance of FIG. 1.

[0025] FIG. 11 is a detail sectional view of the appliance of FIG. 1 taken from detail 11 of FIG. 5.

[0026] FIG. 12 is a top perspective partially cutaway view of a left end of a cabinet of the appliance of FIG. 1 with a portion of worktop portion of the rail removed for clarity.

[0027] FIG. 13 is a top cutaway view of the return air opening of the left end of the cabinet of FIG. 12 with at least a portion of the worktop portion of the rail removed for clarity.

[0028] FIG. 14 is an exploded top right perspective view of the appliance of FIG. 1 showing the catch pan of FIG. 4D and associated parts.

[0029] FIG. 15 is a sectional view of the appliance of FIG. 1 taken along line 15-15 of FIG. 14.

[0030] FIG. 16 is a detail sectional view of the appliance of FIG. 1 taken from detail 16 of FIG. 15.

[0031] FIG. 17 is a top perspective view of the catch pan of FIG. 4D.

[0032] FIG. 18 is a bottom perspective view of the catch pan of FIG. 4D.

[0033] FIG. 19 is a top perspective view of the cover of FIG. 4E.

[0034] FIG. 20 is a bottom perspective view of the cover of FIG. 4E.

[0035] FIG. 21 is a top plan view of the appliance of FIG. 1.

[0036] FIG. 22 is a detail top perspective view of the worktop cavity of the appliance of FIG. 1 showing a thermal break defining a perimeter of the worktop cavity.

[0037] FIG. 23 is a sectional view of the worktop portion of the appliance of FIG. 1 taken from line 23-23 of FIG. 22.

[0038] FIG. 24 is a detail top perspective view of the appliance of FIG. 1 showing the catch pan of FIG. 4D overlapping with an adjacent catch pan.DETAILED DESCRIPTION

[0039] The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, and / or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and / or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0040] The following description is provided as an enabling teaching of the present devices, systems, and / or methods in their best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects described herein, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

[0041] As used throughout, the singular forms “a,”“an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a quantity of one of a particular element can comprise two or more such elements unless the context indicates otherwise. In addition, any of the elements described herein can be a first such element, a second such element, and so forth (e.g., a first widget and a second widget, even if only a “widget” is referenced).

[0042] Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another aspect comprises from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about” or “substantially,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0043] For purposes of the current disclosure, a material property or dimension measuring about X or substantially X on a particular measurement scale measures within a range between X plus an industry-standard upper tolerance for the specified measurement and X minus an industry-standard lower tolerance for the specified measurement. Because tolerances can vary between different materials, processes and between different models, the tolerance for a particular measurement of a particular component can fall within a range of tolerances.

[0044] As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description comprises instances where said event or circumstance occurs and instances where it does not.

[0045] The word “or” as used herein means any one member of a particular list and also comprises any combination of members of that list. The phrase “at least one of A and B” as used herein means “only A, only B, or both A and B”; while the phrase “one of A and B” means “A or B.”

[0046] As used herein, unless the context clearly dictates otherwise, the term “monolithic” in the description of a component means that the component is formed as a singular component that constitutes a single material without joints or seams except those resulting by re-shaping of the material.

[0047] To simplify the description of various elements disclosed herein, the conventions of “left,”“right,”“front,”“rear,”“top,”“bottom,”“upper,”“lower,”“inside,”“outside,”“inboard,”“outboard,”“horizontal,” and / or “vertical” may be referenced. Unless stated otherwise, “front” describes that end of the appliance nearest to and occupied by a user of the appliance; “rear” is that end of the appliance that is opposite or distal the front; “left” is that which is to the left of or facing left from a person standing in front of the appliance and facing towards the front; and “right” is that which is to the right of or facing right from that same person. “Horizontal” or “horizontal orientation” describes that which is in a plane extending from left to right and aligned with the horizon. “Vertical” or “vertical orientation” describes that which is in a plane that is angled at 90 degrees to the horizontal.

[0048] In one aspect, a refrigerated appliance and associated methods, systems, devices, and various apparatuses are disclosed herein. In one aspect, the refrigerated appliance can comprise a first refrigerated portion comprising a first refrigerated compartment and a second refrigerated portion comprising a second refrigerated compartment. The refrigerated appliance can further comprise a refrigerated catch pan.

[0049] Maintaining food product at proper temperatures in a refrigerated appliance can be challenging, especially during industry-standard (e.g., NSF / ANSI Standard 7) test conditions that require maintenance of both rail temperatures (i.e., temperatures of special simulated food material stored in pans positioned in the rail) and cabinet temperatures within proper ranges, e.g., 0.6° C. to 5.0° C. for the rail box car average temperatures using the special simulated food material and 0° C. to 4.4° C. for the lagged cabinet temperatures. Because of the harsh environment found in a commercial kitchen in which many appliances are used, these temperatures must usually be maintained with the appliance in an ambient environment defining an ambient temperature that is usually higher than typical room temperature. For example, NSF / ANSI Standard 7 test conditions typically require an ambient temperature during testing of 86° F., but some actual use conditions can reach up to around 100° F. on the warm end or down to around 45° F. on the cold end. Cooling with expensively manufactured cabinets in which refrigerant or a eutectic fluid (e.g., a liquid having similar properties to anti-freeze liquid used in motor vehicle) circulates through the walls is not a practical or cost-effective option for some users.

[0050] In addition, a typical appliance comprising a raised rail typically also comprises a rail cover for hygienic and other reasons. Because closing the cover can significantly lower the temperature of the rail and users are either not able to or accustomed to manually make the adjustments necessary to avoid freezing of product, which can result in spoilage, users often remove food product from the rail and store elsewhere whenever the appliance and / or the rail will be unattended for more than a short period (e.g., overnight). One or more of the challenges associated with these and other issues can be solved by the structures and methods disclosed herein.

[0051] FIG. 1 is a perspective view of a refrigerated appliance 100 in accordance with one aspect of the current disclosure. The appliance 100 can comprise a cabinet body or base 110 and a rail body or rail 120. The base 110 and the rail 120 can together form a cabinet 105 of the appliance 100. The rail 120 can extend or protrude vertically from and above the base 110. In some aspects, the rail 120 can extend the full length of the base 110. In some aspects, the rail 120 can extend only partially across the base 110. The appliance 100 and, more specifically, the base 110 thereof can comprise one or more closure devices 130. In some aspects, as shown, the closure device 130 can be or can comprise a door, which can be hinged on one side or another of the closure device 130. More specifically, a handle 135 attached to or defined in the closure device 130 can facilitate opening of the closure device 130. Similarly, the appliance 100 and, more specifically, the rail 120 thereof can comprise one or more closure devices 140. In some aspects, as shown, the closure device 140 can be or can comprise a cover or lid, which can be hinged on one side or another of the closure device 130. More specifically, a handle 145 attached to or defined in the closure device 140 can facilitate opening of the closure device 140. The closure device 140 and the closure device 130 can be oriented in different planes.

[0052] In some aspects, as shown, the rail 120 can comprise multiple portions, which can be separably assembled to each other. The rail 120 can comprise a first portion 122, which can define the first refrigerated portion 101 and, more specifically, an opening 208 (shown in FIG. 4A) and the pan storage cavity 528 (shown in FIG. 5). The rail 120 can comprise a second portion 124, which can comprise one or more walls 125 extending from and / or past the first portion 122. The walls 125 can extend in a vertical or substantially vertical direction. The second portion 124 can shield the first portion 122 from convective heat transfer from the surrounding ambient air into pans 510 (shown in FIG. 5) stored in the pan storage cavity 528. The rail 120 can comprise a third portion 126, which can comprise one or more walls 127 and / or extending from and / or past the first portion 122 and / or the second portion 124. Like the second portion 124, the third portion 126 can shield the first portion 122 from convective heat transfer from the surrounding ambient air into pans 510 (shown in FIG. 5) stored in the pan storage cavity 528. The third portion 126 can additionally comprise walls 129. The walls 129 can extend in a horizontal or substantially horizontal direction. One or more of the walls 129 can define one or more storage cavities 128, which can be sized and otherwise configured to receive and, more specifically, slideably receive one or more worktop supports 250, one or more catch pans 260, and / or one or more covers 270. In some aspects, as shown, the storage cavities 128 can be sized and otherwise configured to receive each of the covers 270. In some aspects, the first portion 122, the second portion 124, and / or the third portion 126 can define a polygonal shape in cross-section.

[0053] The appliance 100 can comprise a refrigeration circuit or refrigeration system 150 (shown in FIG. 3), which can be housed within a portion of the base 110 and, more specifically, a cavity defined therein. Access panels 160 such as, for example and without limitation, one or more of a front access panel 162, a side access panel 164 (shown in FIG. 3), and a rear access panel 166 (shown in FIG. 3) can selectively provide or block access to the refrigeration system 150 and / or other components of the appliance 100 to which a user need not have immediate access. In some aspects, as shown, the base 110 can be supported by a plurality of supports 190 (shown in FIG. 2), which can be wheels or casters by which the appliance 100 can be rolled from one location to another. In some aspects, the supports 190 can comprise one or more legs. More generally, the appliance 100 can define one or more “sections” in which each section can define a main opening 118, which the one or more closure devices 130 can be configured to selectively cover. More specifically, each of the closure devices 130,140 can be configured to limit leakage of air from an ambient environment to and from the base 110 or the rail 120 or any portion thereof. In some aspects, the opening 208 of the rail 120 or a portion thereof and the opening 118 of the base 110 or a portion thereof can face in different directions. More specifically, the opening 208 can face generally upward, and the opening 118 of the base 110 can face generally forward. In some aspects, as shown, the appliance 100 can be a two-section refrigerated preparation table. In other aspects, the appliance 100 can comprise or define any number of sections.

[0054] The sections or the openings 118 defined therein can be positioned adjacent to each other with a frame, mullion, or divider 112 positioned therebetween. The divider 112 can extend in a vertical direction and can be insulated. More specifically, the divider 112 or any similar structure can encapsulate an insulating material such as blown or block foam. The divider 112 can be heated to reduce or eliminate condensation that might otherwise form on an outer surface thereof because the appliance 100 is refrigerated. As disclosed herein, “refrigerated” means broadly that which is cooled or that which cools or keeps cool, whether the temperature of the cooled space, cooled product, or other disclosed elements are above or below 32° F., the freezing point of water. In some aspects, as shown, the closure device 130 can be or can comprise a drawer or a set of drawers, which be supported inside a drawer frame secured to the base 110. Such a drawer frame or equivalent structure can comprise a frame, mullion, or divider 114, which can be positioned between adjacent drawers. In some aspects, as shown, the closure device 140 can be or can comprise a rail cover or lid. In some aspects, the closure device 140 can be or can comprise more than one rail cover or lid.

[0055] The appliance 100 can define a width W measured in a direction parallel with a front of the appliance 100. The appliance 100 can define a depth D measured in a direction parallel with a side of the appliance 100. The appliance 100 can define a height H measured in a vertical direction of the appliance 100. In some aspects, the appliance 100 can define an internal volume of a cabinet or base cavity 218, which can measure between 11 cubic feet and 30 cubic feet. In some aspects, the internal volume of the base cavity 218 can be outside of this range.

[0056] The appliance 100 can comprise a controls system 170, which in some aspects can comprise a primary controller or controller 172 (shown in FIG. 3) and a secondary controller 174. The primary controller 172 can be configured to control overall operation of the appliance 100 and, more specifically, cooling of the rail 120. Meanwhile, the secondary controller 174 can be configured to control cooling of the base 110. As shown, the secondary controller 174, which can comprise a control interface 175, can be secured to the front access panel 162. In some aspects, as will also be described herein, a single controller 172 of the controls system 170 can control all aspects of cooling of the appliance 100.

[0057] FIGS. 2 and 3 are various views of a lower left portion of the appliance 100 of FIG. 1. FIG. 2 is a top front left perspective view of a lower left portion of the appliance 100, and FIG. 3 is a partially exploded rear perspective view of the lower left portion of the appliance 100 showing various access panels 160 removed and offset from the appliance 100. Again, the access panels 160 can comprise one or more of the front access panel 162, the side access panel 164, and the rear access panel 166, which are shown removed and offset from the appliance 100. One or more of the access panels 160 can define openings 168, which can facilitate ventilation of, i.e., circulation of air to and from, the refrigeration system 150. The appliance 100 can comprise a power cord 70, which can be configured to supply power to the appliance 100 overall, including the refrigeration system 150. The appliance 100 can comprise the controller 172, which can again be a primary controller and can be configured to control overall operation of the appliance 100 including operation of the refrigeration system 150.

[0058] FIGS. 4A-4E are various views of the appliance 100 of FIG. 1. FIG. 4A is a top front perspective view of the appliance of FIG. 1. The rail 120 can comprise a worktop portion 202 and a rail portion 203. Again, as also shown, the appliance 100 can comprise one or more of the worktop supports 250, upon which a user can cut, assemble, and / or otherwise process a product (e.g., food ingredients for use in preparing a pizza, sandwich, or other food product). In some aspects, the work surface and, more specifically, the one or more worktop supports 250 can be defined by one or more grates or grills, each of which can be formed from or comprise wire and, more specifically, metal wire welded into a frame. The one or more worktop supports 250 can be secured to or otherwise restrained to a certain position on the rail 120 and, more specifically, the worktop portion 202 with brackets 255. More specifically, as shown, each of the brackets 255 can restrain movement of the one or more worktop supports 250 in a lateral or left-to-right direction of the appliance 100.

[0059] FIG. 4B is a detail top front perspective view of the appliance 100 of FIG. 1, FIG. 4C is a detail top front perspective view of a right end of the worktop portion 202 of the appliance 100 of FIG. 1 with the worktop support 250 in place, and FIG. 4D is a detail top front perspective view of a right end of the worktop portion 202 of the appliance 100 of FIG. 1 with a portion of one of the worktop supports 250 removed. The worktop portion 202 can comprise a worktop body 210 and a worktop cavity 280, which can be a recess defined in the worktop body 210. The appliance 100 can comprise the catch pan 260, which can be received within the worktop cavity 280. The catch pan 260 can be configured to catch or collect food ingredients that drop through the worktop support 250 during use of the appliance 100. By catching and maintaining a temperature of the food ingredients, the food ingredients can be returned to the rail and / or otherwise reused, which can reduce waste and thereby operational costs. The worktop portion 202 can further comprise a support bracket 420, which can be secured to a front edge of a surrounding or remaining portion of the worktop portion 202 and can extend past a remaining portion of the front edge of the worktop portion 202 and can provide additional support for the one or more worktop supports 250.

[0060] FIG. 4E is a detail top front perspective view of a right end of the worktop portion 202 of the appliance 100 of FIG. 1 with a portion of the worktop support 250 removed and showing the plug or cover 270, which can be received within the worktop portion 202. The cover 270 can sealably cover or otherwise cover the worktop cavity 280 and thereby can help maintain a temperature of the air inside the worktop cavity 280. The appliance 100 and, more specifically, the worktop portion 202 can comprise a thermal break 450, which can slow heat transfer into the rail 120. More specifically, the thermal break 450 can comprise or be formed from a non-thermally conductive material such as, for example and without limitation, a plastic or polymer resin.

[0061] FIG. 5 is a sectional view of the appliance 100 of FIG. 1 taken along line 5-5 of FIG. 1 showing the closure devices 130 (more specifically, a pair of drawers in a left section of the appliance 100) replaced with a door as the closure device 130 in the left section. One or more walls of each of the base 110 and the rail 120 can be insulated. For example and without limitation, the walls can be insulated with blown or block foam, which can be a polyurethane foam. Either or both of the closure devices 130,140 can be similarly insulated. The rail 120 can define a first refrigerated portion 101 and, more specifically, a first insulated enclosure or first refrigerated compartment 103 thereof. The base 110 can define a second refrigerated portion 102 and, more specifically, a second insulated enclosure or second refrigerated compartment 104 thereof. The rail 120 can be lowered and then compressed onto the base 110 and a seam defined therebetween can be sealed by a thermal break 219. The rail 120 can be secured by a series of fasteners 290 along the front and rear leading edges of the cabinet. As shown, a top surface of the rail 120 can be angled with respect to the horizontal. More specifically, the top surface of the rail 120 can be angled at or at least 5 degrees with respect to the horizontal.

[0062] The appliance 100 and, more specifically, the cabinet 105 and the base 110 can comprise an interior surface 211 and an exterior surface 212. The cabinet 105 can be defined by one or more of a bottom wall 213, a rear wall 214, side walls 215, a front frame 216, and an evaporator enclosure 217. The thermal break 219, which can be formed from a non-conductive or insulating material such as plastic, can interrupt or limit heat transfer between the exterior surface 212 and the interior surface 211 at any one or more connections therebetween. The cabinet 105, including in some aspects the closure device 130 and both the base 110 and the rail 120, can define the cabinet or base cavity 218. A portion of the base cavity 218 defined by the evaporator enclosure 217 can be separated from a remaining portion of the base cavity 218 defined by walls such as, for example and without limitation, the walls 213,214,215a,b by a return air duct 204.

[0063] The appliance 100 and, more specifically, the cabinet 105 and the rail 120 can comprise an interior surface 221 and the exterior surface 222 defined by the worktop portion 202 and the rail portion 203. More specifically, the rail 120 can comprise a rear wall 224, side walls, and a front wall 226. As with the thermal break 450, one or more other thermal breaks (not shown) can additionally or instead interrupt or limit heat transfer between the exterior surface 222 and the interior surface 221 at any one or more connections therebetween. More specifically, tape formed from an insulating material (e.g., double-sided tape comprising any insulating carrier, backing, or substrate) can be positioned between two adjoining panel formed from a conducting material to provide a thermal break. In some aspects, as shown, a panel 521 defining the interior surface 221 can comprise or be formed from a thermally conductive material such as, for example, metal. More specifically, the panel 521 can comprise or be formed from a corrosion-resistant metal such as stainless steel. In some aspects, a portion of the interior surface 221 and, more specifically, some or all of the interior surface 221 in contact with the thermal break 219 of the base 110 can be a thermal break, which can be formed from a non-conductive or insulating material such as plastic. In some aspects, the panel 521 can be planar or flat and can define both a ceiling of the base cavity 218 and the bottom of the worktop cavity 280. The rail 120, including in some aspects the closure device 140 (shown in both open and closed positions), can define a rail cavity 228 and the opening 208 defined at an outer or upper end thereof. The rail cavity 228 can be separated or divided into separate portions by a rail duct or duct 205, which can be secured to a surrounding portion of the rail 120 with fasteners 229. As shown, the rail duct 205 can be secured to one or more of the rear wall 224, the side walls 225 (shown in FIG. 4A), and the front wall 226 with the fasteners 229, which can be screws. The rear wall 224 and any portion thereof can be substantially vertical (closer to a vertical orientation than to a horizontal direction) or vertical (aligned with the vertical orientation).

[0064] The appliance 100 and, more specifically, the cabinet 105 can comprise various other panels or ducts. The cabinet 105 can comprise a main cabinet duct or roof duct 206, which can be secured to an underside of the rail 120 and can extend in a horizontal direction front to rear and left to right across a roof of the appliance 100 defined by the interior surfaces 211,221. The cabinet 105 can comprise a cabinet fan assembly 207, which can be coupled to the roof duct 206 and can be configured to deliver cold air to the base cavity 218 during normal operation. The appliance 100 can comprise a control interface 173, which can define an input to the controller 172 (shown also in FIG. 4B), which again can be configured to control overall operation of the appliance 100 and, more specifically, cooling of the rail 120. In some aspects, as shown, the control interface 173 can be positioned inside the appliance and, more specifically, on an interior surface such as the interior surface 211 of the second refrigerated portion 102. In some aspects, the control interface 173 can be positioned on an exterior surface such as the control interface 175 can be positioned on a surface of the front access panel 162.

[0065] The appliance 100 can comprise one or more storage components 410, each of which can receive stored product, e.g., food product in storage containers, thereupon. In some aspects, as shown, each of the storage components 410 can comprise or can be a shelf. In some aspects, each of the storage components 410 can comprise or can be a shelf slide or a set of shelf slides configured to receive shelves extending therebetween. In some aspects, each of the storage components 410 can comprise or can be a pan slide or a set of pan slides configured to receive storage pans (not shown) extending therebetween.

[0066] The rail duct 205 can define openings 480 in each of a rear wall 424 and a front wall 426. More specifically, the openings 480a,b can be configured to allow transmission or flow of air from behind the rail duct 205 and into a rail storage cavity or pan storage cavity or cavity 528 defined at least in part by the rail duct 205. In some aspects, as shown, each of the openings 480 can be a louver. In some aspects, each of the openings 480 can be a slot.

[0067] The appliance 100 and, more specifically, the raised rail 120 thereof can comprise or be configured to receive a plurality of food pans or pans 510. The plurality of pans 510 can comprise any desired combination of the pans 510, which typically are fractional sizes of a full-size “hotel” pan and configured to hold stored product such as, for example and without limitation, food ingredients for both refrigerated storage, display, and dispensing during a commercial food preparation process such as making a pizza or a sandwich. A full-size hotel pan can be and typically is sized to fit within a rectangular opening measuring 12 inches by 20 inches. Common or standard fractional sizes of a pan 510 include 1 / 9, ⅙, ¼, ⅓, ½ regular or short, and ½ long sizes. Fractional pans 510 used in combination can be configured to fit within the same pan opening as one full-size pan 510. For example, three ⅓-size pans 510 are typically configured to fit within the same pan opening as the full-size pan 510. In some aspects, each of the pans 510 can measure approximately 4 inches deep. In some aspects, each of the pans 510 can measure approximately 6 inches deep. In some aspects, a depth of each of the pans 510 can be smaller or greater. A variety of sizes can be combined to hold different amounts of food ingredients in different amounts, and positions to facilitate flexibility while using the appliance 100 and at the same time allow thorough cleaning of all that touches the food ingredients by removal and cleaning of the pans 510 and even the rail duct 205 as well as any exposed surfaces of surrounding portions of the appliance 100. The pan storage cavity 328 can be configured to receive one or more of the food pans 510.

[0068] In some aspects, for example and without limitation, the pan storage cavity 328 of a one-section appliance 100 defining a width W (shown in FIG. 1) of 46 inches can be configured to receive six ⅓-size pans; the pan storage cavity 328 of a two-section appliance 100 defining a width W of 60 inches can be configured to receive eight ⅓-size pans; the pan storage cavity 328 of a two-section appliance 100 defining a width W of 67 inches can be configured to receive nine ⅓-size pans; and the pan storage cavity 328 of a three-section appliance 100 defining a width W of 93 inches can be configured to receive twelve ⅓-size pans. One or more pan dividers (not shown) can be positioned between adjacent pans 510 of the plurality of pans 510.

[0069] The closure device 140 or any portion thereof of the rail 120 can be secured to the rail 120 and, more specifically, the second portion 124 and / or the third portion 126. The closure device 140 can slideably and / or hingeably open and close. More specifically, the closure device 140 and any portion thereof can open to one or more open positions, at which a position of the closure device 140 can be maintained indefinitely or until a user of the appliance 100 is ready to return the closure device 140 to a closed position also shown.

[0070] FIG. 6A is a schematic view of the refrigeration system 150 of the appliance 100 of FIG. 1. The refrigeration system 150 can comprise a condensing unit 610, an evaporating unit 650, and a refrigerant (not shown) received within each of the condensing unit 610 and the evaporating unit 650. The refrigeration system 150 can comprise tubing 605, which can join each of the components of the refrigeration system 150 configured to receive the refrigerant and can itself form at least a part of such components. The refrigerant can be configured to flow through each of the condensing unit 610 and the evaporating unit 650 and, ultimately, to remove heat from at least one of air and stored product received within the appliance 100.

[0071] The condensing unit 610 can comprise a compressor 620 and a condenser 630 in fluid communication with each other. The compressor 620 can be configured to transform a low-pressure gas entering the compressor 620 into a high-pressure hot gas exiting the compressor 620 by compression of the refrigerant, which can be a refrigerant such as R290, commonly known as propane. In some aspects, the refrigerant can be another gas able to facilitate heat transfer.

[0072] The condenser 630 can comprise tubing such as the tubing 605, which can be routed as desired, including in a serpentine fashion, to increase a surface area of the condenser 630 exposed to air flow and can by its shape and material facilitate heat transfer. In some aspects, the condenser 630 can further comprise fins, which can be coupled to the tubing and can further increase the surface area of the condenser 630 exposed to the air flow and can by its shape and material facilitate heat transfer.

[0073] The condensing unit 610 can further comprise a condenser fan 640, which can comprise a motor, a shaft coupled to the motor, and a fan blade coupled to the shaft. The condenser fan 640 can be configured to drive or blow air past or through the condenser 630 (and, less importantly, also the compressor 620) to remove heat therefrom (i.e., the condenser 630 can be configured to release heat into the air passing through the condenser 630). More specifically, As the condenser 630 is cooled by air driven by the condenser fan 640, the condenser 630 can transform the refrigerant therein from a high-pressure hot gas to a high-pressure liquid, thereby condensing the refrigerant.

[0074] The condensing unit 610 can comprise a filter-dryer 635, which can protect the refrigeration system 150 against contaminants and moisture. The condensing unit 610 can comprise a high-pressure safety switch 637, which can protect the refrigeration system 150 against high pressures by cutting off the compressor 620 and other components when a threshold high pressure is measured.

[0075] The evaporating unit 650 can be in fluid communication with the condensing unit 610. More specifically, the evaporating unit 650 can both receive the refrigerant from the condensing unit 610 and return the refrigerant to the condensing unit 610 in a continuous loop. The evaporating unit 650 can comprise a refrigerant metering device 660 and an evaporator 670 in fluid communication with each other.

[0076] The refrigerant metering device 660 can restrict or meter flow of the high-pressure liquid refrigerant from the condenser 630. The refrigerant metering device 660 can thereby transform the refrigerant from high-pressure lower temperature liquid to a low-pressure and low temperature liquid. In some aspects, the refrigerant metering device 660 can be a thermostatic expansion valve, sometimes referred to as a TXV or TEV. The TXV can be configured to dynamically adjust an orifice defined therein based on operation of the system and thereby adjust flow of the refrigerant through the TXV. More specifically, the TXV can be configured to accomplish such adjustment by placement of a bulb of the TXV on a suction line of the refrigeration system 150 (i.e., a section of the tubing 605 between the evaporator 670 and the compressor 620) and, in the process of sensing a temperature of the suction line with the bulb, causing a gas inside the bulb to effect opening and closing and, more generally, adjustment of the orifice. In some aspects, the refrigerant metering device 660 can be a capillary tube, which can define an internal diameter of, for example and without limitation, between 1.0 and 1.5 mm; and a length of, for example and without limitation, between 2000 and 2500 mm. While lacking certain features of the TXV, an inner diameter and length of the capillary tube can be set when building the refrigeration system 150 to sufficiently transform the properties of the refrigerant by the time the refrigerant enters the evaporator 670. In some aspects, the refrigeration system can comprise a suction line heat exchanger 665. More specifically, the refrigerant metering device 660, at least in the form of a capillary tube, can be brought within mating contact with the suction line over a length of each of the refrigerant metering device 660 and the suction line and thereby facilitate vaporization of any refrigerant in the suction line still in a liquid state after passage through the evaporator 670. The suction line heat exchanger 665 can protect the compressor 620 against “flooding” of the compressor with liquid refrigerant and in general can improve cooling performance of the refrigeration system 150.

[0077] More specifically, the evaporator 670 can comprise tubing such as the tubing 605, which can be routed as desired, including in a serpentine fashion, to increase a surface area of the evaporator 670 exposed to air flow and can by its shape and material facilitate heat transfer. In some aspects, the evaporator 670 can further comprise fins, which can be coupled to the tubing and can further increase the surface area of the evaporator 670 exposed to the air flow and can by its shape and material facilitate heat transfer.

[0078] The evaporating unit 650 can further comprise one or more evaporator fans 680, which can be configured to move air across the evaporator 670. Each of the evaporator fans 680 can comprise a motor, a shaft coupled to the motor, and a fan blade coupled to the shaft. Each of the evaporator fans 680 can be configured to drive or blow air past or through the evaporator 670 to absorb heat therefrom (i.e., the evaporator 670 can be configured to absorb heat from the air passing through the evaporator 670). As the evaporator 670 is cooled by air driven by the evaporator fans 680, the evaporator 670 can transform the refrigerant therein from a low-pressure low-temperature gas to a low-pressure higher-temperature gas, thereby evaporating the refrigerant. In some aspects, the evaporating unit 650 can be configured to supply cool air to an air plenum system of the appliance 100, which can be configured to cool the appliance 100. The air plenum system can comprise any of the cavities described elsewhere herein and configured to receive air flow.

[0079] The evaporating unit 650 can comprise a defrost thermistor or sensor 632 (shown in FIG. 6B), which can facilitate defrost of the evaporator 670 and thereby protect the refrigeration system 150 against the consequences of ice and / or frost on the evaporator 670, which can block air flow across the evaporator 670 and adversely impact heat transfer. The defrost thermistor 632 can come with the controller 172 and can be as specified from Danfoss A / S (e.g., Part No. 077F 08790). The evaporating unit 650 can comprise a defrost heater 634, which can protect the refrigeration system 150 against ice and / or frost on the evaporator 670 by applying heat to the evaporator 670 when a defrost cycle is initiated. More specifically, the defrost heater 634 can be an electric heater and can use conduction and / or radiation to apply heat to the evaporator 670. The evaporating unit 650 can comprise a defrost safety thermostat 636, which can protect the evaporator 670 and, more generally, the appliance 100 against overheating by prolonged operation of the defrost heater 634 that is not otherwise terminated. The evaporating unit 650 can comprise a drain collection device 638 (shown in FIG. 9A), which can further protect the refrigeration system 150 against ice and / or frost by directing moisture away from the evaporator 670 and from the evaporating unit 650 and can itself be heated as desired to protect against ice and / or frost on the drain collection device 638. In some aspects, the drain collection device 638 can be or can comprise a tray or pan.

[0080] FIG. 6B is a perspective view of the refrigeration system 150 of FIG. 6A. The condensing unit 610 can comprise the aforementioned components including the compressor 620 and the condenser 630. As shown, the condensing unit 610 can further comprise a condensate evaporating system 625. The condensate evaporating system 625 can comprise a collection device 627 configured to hold liquid condensate drawn from the evaporating unit 650. As shown, a drain tube 655 can capture the liquid condensate and direct same to the collection device 627 of the condensate evaporating system 625. In some aspects, a guide 657 can be secured to one of the condensing unit 610 and a surrounding structure of the refrigeration system 150 or, more generally, the appliance 100. The guide 657 can direct liquid condensate from the drain tube 655 to the collection device 627. In some aspects, the condensate evaporating system 625 can comprise a heating element 629. In some aspects, the heating element 629 can be a portion of the tubing 605 that is positioned between the compressor 620 and the condenser 630 and is filled with high-temperature gas during normal operation. In some aspects, the heating element 629 can be an electric heater or other heater. The heating element 629 can be received into the collection device 627.

[0081] In some aspects, the components of the condensing unit 610 can be assembled separately in a modular fashion, and the condensing unit 610 can be installed as an assembly. The condensing unit 610 for smaller versions of the appliance 100 such as, for example and without limitation, a one-section appliance 100 defining a width W (shown in FIG. 1) of 46 inches and a two-section appliance 100 defining a width W of 60 inches can be Model UMC3130U having a compressor capacity of approximately ⅓ horsepower and a heat rejection capacity of 800 BTU / hour or more; and the condensing unit 610 for larger versions of the appliance 100 such as, for example and without limitation, a two-section appliance 100 defining a width W of 67 inches and a three-section appliance 100 defining a width W of 93 inches can be Model EMC3134U having a compressor capacity of approximately ½ horsepower and a heat rejection capacity of 900 to 1,000 BTU / hour or more, both products being available from Embraco LLC and / or Embraco North America of Duluth, Georgia, U.S.A.

[0082] The evaporating unit 650 can comprise an evaporator shroud 685, which can be configured to position and support the evaporator fans 680 and can direct air through the evaporator 670. More specifically, the evaporator shroud 685 can comprise a first panel 682, to which the evaporator fans 680 can be secured and which can define matching openings (not shown) therein for passage of air through the evaporator fans 680. The evaporator shroud 685 can comprise a second panel 684, which can fit close to or even flush with a side of the evaporator to prevent short cycling of air around the evaporator and / or contain heat applied to the evaporator 670 during a defrost cycle. A quantity of the evaporator fans 680 can vary based on the air flow needed through the evaporator 670. For example and without limitation, the one-section appliance 100 defining a width W of 46 inches and the two-section appliance 100 defining a width W of 60 inches can comprise a pair of evaporator fans 680; and the two-section appliance 100 defining a width W of 67 inches and the three-section appliance 100 defining a width W of 93 inches can comprise three evaporator fans 680. Each of the evaporator fans 680 can be sized based on the size of the appliance 100 but in some aspects can deliver at least or approximately 106 CFM. Each of the evaporator fans 680 can be a Model UF12A-series alternating current (AC) product measuring 120 mm square and 38 mm thick and available from Mechatronics Fan Group of Preston, Washington, U.S.A. Various fasteners (not shown) can assemble the components of the condensing unit 610 and the evaporating unit 650 together and to each other.

[0083] In some aspects, as shown, the appliance 100 can comprise—and need only—one and only one instance of the refrigeration system 150. In some aspects, as also shown, the refrigeration system 150 can comprise—and need only—one and only one compressor 620 for cooling (e.g., each of the first refrigerated portion, the second refrigerated portion, and the worktop cavity). In such aspects, it can be beneficial in terms of cost, energy efficiency, serviceability, and other reasons for the appliance 100 to require only a single refrigeration system 150 and / or a single compressor 620.

[0084] FIG. 7 is a schematic view of an airflow circuit 700 of the appliance 100 of FIG. 1. As shown, air can be pulled from the base cavity 218 of the cabinet or base 110. The air can then be pulled through the evaporator 670 and through the evaporator fans 680 by the evaporator fans 680. The air can then be pulled through the rail cavity 228 and, more specifically, the pan storage cavity 428 defined by the rail 120. The air can then be also pulled from the rail 120 through the one or more cabinet fan assemblies 207 by the cabinet fan assemblies 207 into the base cavity 218 or can bypass the base cavity 218 and return to the evaporator 670. In some aspects, as shown, the evaporator fans 680 can be positioned above or on an outlet side of the evaporator 670 and can pull air through the evaporator 670. In some aspects, the evaporator fans 680 can be positioned below or on an inlet side of the evaporator 670 and can push air through the evaporator 670.

[0085] FIG. 8 is a detail front perspective view of a left side of the cabinet 105 of the appliance 100 of FIG. 1 showing the control interface 173 of the primary controller 172 and the control interface 175 of the secondary controller 174. The control interface 173 of the primary controller 172 can be configured to control an air temperature of the rail portion 203 (shown in FIG. 5) of the rail 120; and the control interface 175 of the secondary controller 174 can be configured to control an air temperature of an interior cavity such as the base cavity 218 of the base 110. In some aspects, as shown, the control interface 173 can comprise a dial control. In some aspects, the primary controller 172 can be a Model ERC113C-series product from Danfoss A / S of Nordborg, Denmark. In some aspects, the primary controller 172 can control operation of the compressor 620, the defrost system, the evaporator fans 680, and can switch between “day” mode and “night” mode as discussed in U.S. application Ser. No. 17 / 889,249, filed on Aug. 16, 2022. Additionally, however, each of the one or more closure devices 140 and, more specifically, each of the one or more rail lids, can trigger a transition between day mode and night mode and thereby automatically adjust the temperature setpoint of the rail 120 by the unit sensing a position of the closure device 140 and making the adjustment. More specifically, in the case of multiple closure devices 140, a position of each closure device 140 can be separately monitored by a separate sensor 450, which can be exemplarily positioned relative to each closure device 140 as disclosed in U.S. application Ser. No. 17 / 889,249 or otherwise as desired. In some aspects, for example and without limitation, the sensor 450 for each closure device 140 can be positioned in a hidden area of the third portion 126 of the rail 120 (for example and without limitation, between where individual covers 270 are positioned in the storage area 128, and housed within enclosures as desired). More specifically, the sensor 450 can be a door switch with a rotating contact element configured to selectively engage and disengage with a surface of the closure device 140. During use, returning any one of the closure devices 140 to its storage location and thereby exposing a portion of the rail 120 can result in an adjustment to day mode—even if the other closure devices 140 are still covering the remaining portion(s) of the rail 120—and with the adjustment can increase cooling to the rail. In some aspects, the secondary controller 174 can be a Model E31B-series product from Ascon Technologic S.r.L. of Vigevano, Italy. In some aspects, the secondary controller 174 can control operation of the cabinet fans 1010.

[0086] The front access panel 162 can comprise an air inlet opening 868, through which the condenser fan 640 (shown in FIG. 6B) can draw air across the condenser 630 (shown in FIG. 6B). In some aspects, the air inlet opening 868 can be defined and / or covered by a grill 864. More specifically, the grill 864 can comprise a filter 866, which can be washable and / or replaceable with or without tools, depending on user requirements.

[0087] FIG. 9A is a sectional view of the appliance of FIG. 1 taken along line 9A-9A of FIG. 5, and FIG. 9B is a detail sectional view of the appliance 100 taken along line 9B-9B of FIG. 9A in accordance with another aspect of the current disclosure and showing only geometry in the cut plane. As will be described in further detail below, airflow alone through the appliance 100 and, more specifically, the first refrigerated portion 101 can distribute cold air throughout the pan storage cavity 428 and around each pan 510 (shown in FIG. 5) and can properly maintain air and product temperatures throughout the first refrigerated portion 101.

[0088] The appliance 100 need not use “cold wall” construction to cool the rail portion 203 of the rail 120 properly as in appliances that are typically available. As such, the rail 120 and associated structures can define a non-cold-wall construction, which means that no walls of the first refrigerated compartment or first insulated enclosure 103 nor pan dividers nor ducts between adjacent pans 510 that are configured to be received within the pan storage cavity 428 contain any refrigerated tubing. In an appliance defining “cold wall” construction, either refrigerant or glycol is typically circulated through tubes, which are typically formed from copper and embedded inside the walls of the rail. Rails of such units typically have separate evaporators and sometimes have separate and distinct refrigeration circuits. Such “cold wall” rails must typically be defrosted manually, which under some circumstances and without care cause damage to the rail caused, for example, by forceful removal of built-up ice that is not an issue with the structures disclosed herein. Again, in contrast, the appliance 100 need comprise only a single refrigeration system 150 and need comprise only a single evaporator 670 together with the one or more cabinet fan assemblies 207, which can be configured to regulate cooling of the cabinet through an air plenum on an as-needed basis. Such a construction can be significantly more expensive to build and less serviceable than the structures and methods disclosed herein.

[0089] Among designs by others using an air-cooled method, air is typically forced from the rail into the cabinet through an open duct regardless of cooling need (i.e., with no dynamic control), which can lead to food product freezing in a cabinet that ordinarily should be maintained above freezing temperatures. In addition, the rail ducts are typically fixed, i.e., not removable, which is an obstacle to regular and / or thorough cleaning. Using one or more of the improvements disclosed herein, however, the rail and cabinet temperatures can be adjusted and controlled automatically and independently.

[0090] The appliance 100 and, more specifically, the first refrigerated portion 101 (which can be defined at least in part by the rail 120) and the second refrigerated portion 102 (which can be defined at least in part by the base 110) can define an intake air cavity 910 therebetween. More specifically, the intake air cavity 910 can be defined between a top surface 901 of the roof duct 206 and the outward-facing surface 422 defined by the bottom wall 423 of the rail duct 205. The roof duct 206 can further define a bottom surface 902. The intake air cavity 910 can be further defined between the interior surface 221 (shown in FIG. 9B) of the rear wall 224 (shown also in FIG. 9B) of the first refrigerated compartment 103 and the outward-facing surface 422 defined by the rear wall 424 of the rail duct 205. As shown, the intake air cavity 910 can be in fluid communication with an evaporator cavity 980, which can be defined by the base 110 of the cabinet 105 and can house the evaporating unit 650 (shown in FIG. 6A) of the refrigeration system 150 (shown in FIG. 6A) and can be configured to receive air supplied by the evaporating unit 650. An inlet duct 920 can separate a supply side 980a of the evaporator cavity 980 from a return side 980b of the evaporator cavity 980. The return air duct 204 can separate the evaporator cavity 980 from the base cavity 218.

[0091] As shown in FIG. 9B, a rail inlet divider or first divider 930 of the rail 120 and, more generally, the appliance 100 can separate the intake air cavity 910 from a communication air cavity 938 configured to receive air that has circulated already through the first refrigerated compartment 103, which can be defined by the rail 120. More specifically, the first divider 930 can separate the intake air cavity 910 from the communication air cavity 938 along an entire length of the roof duct 206. The roof duct 206 itself can comprise a bottom panel 903, a rear panel 904, a front panel 906, side panels, and a mounting flange 927.

[0092] With the first divider 930 positioned as shown and sealing a gap between the rail duct 205 and the roof duct 206, air circulating from the evaporator cavity 980 into the intake air cavity 910 can be encouraged, as a general matter, to continue in the longitudinal direction 403 of the rail duct 205 (shown in FIG. 9A) down a length of the first refrigerated compartment 103. Along the way and upon reaching the far end of the intake air cavity 910 distal from the evaporator cavity 980, the intake air cavity 910 can naturally direct all air to the rear and up between the rear wall 424 of the rail duct 205 and the rear wall 224 of the rail 120. The rail duct 205 can then be configured to receive such cool air through the openings 480a. Thus, below the rail duct 205, the intake air cavity 910 can be an air plenum and can be configured to pressurize the air from the evaporator cavity 980 and evenly distribute the air throughout the first refrigerated compartment 103, which again can be defined by the rail 120.

[0093] The air can flow through the openings 480a and can flow through other openings and then into the rail cavity 228. Due to geometric considerations, in some aspects the air can flow differently in a left front corner of the rail. The air can circulate through the rail cavity 228 and around the plurality of pans 510 (shown in FIG. 5) positioned therein. The air can then flow through the openings 480b and into the communication air cavity 938 in a direction towards the base cavity 218. Again, the openings 480a, b can be sized and positioned to evenly distribute air in the pan storage cavity 428 such that each pan 510 receives a similar amount of air flow and can be maintained at temperatures that are within a predetermined range.

[0094] The properties (e.g., size, locations, and quantities) of the openings 480, including supplemental openings 486a, can be defined in the rail duct 205 as shown to facilitate maintenance of proper temperatures inside the first refrigerated compartment 103 of the first refrigerated portion 101, which can be defined by the rail 120. These properties can be optimized based on simulation of various structures using manufacturing considerations (e.g., the availability of standard tooling), simulation (e.g., computational fluid mechanics or CFM), and actual testing of the appliance. Various other exemplary dimensions and characteristics of the appliance 100 can be based at least in part on spatial constraints (e.g., dimensions of both the base 110 and the rail 120 being based at least in part on the size of fractional hotel pans 510 shown in FIG. 5A, a height of the roof duct 206 being based on at least in part on a thickness or height of a cabinet fan 1010, and various other dimensions based on customer requirements and supplier part specifications).

[0095] The combination of openings 480 can be optimized for each size model and as disclosed herein are based on conditions set by NSF / ANSI (National Sanitation Foundation / American National Standards Institute) Standard 7 for Commercial Refrigerators and Freezers, which specifies in part four-inch-deep half-size pans containing a simulated food material (a special methylcellulose mixture) and an ambient temperature of 86° F. (30° C.). Under the NSF / ANSI Standard 7 test conditions, temperatures measured at certain points inside the pans 510 (shown in FIG. 5A) must remain within a range of 0.6° C. to 5.0° C. over a full four-hour testing period, and lagged temperatures (i.e., temperatures measured by thermocouples placed inside special weighted lags) placed in precise locations inside the base cavity 218 must remain within a range of 0° C. to 4.4° C. over the same testing period.

[0096] In different operating conditions (e.g., deeper pans, a different ambient temperature, air circulation inside room, and / or properties of actual food product stored in the appliance 100 and, more specifically, the rail 120) and even under otherwise compliant NSF / ANSI Standard 7 test conditions, a different combination of openings and other settings can be sufficient to main temperatures at levels satisfactory to a user of the appliance 100 in the different operating conditions. Moreover, other dimensions of the appliance 100 including the size and position of the rail duct 205 and, more generally, the configuration of the rail 120 and various ducting components are similarly optimized based on conditions generally set by NSF / ANSI Standard 7 but can generally also be modified based on different operating conditions. To the degree that a single range of conditions is neither required nor present in actual use of the appliance 100, and to the degree that NSF / ANSI Standard 7 conditions are more exacting than some users require, various combinations are conceivable where user requirements allow for different conditions; and the combinations shown are therefore intended to be exemplary. In some aspects, the modifications that would be appropriate for a change in conditions will be understood by one who is skilled in the art. In some aspects, the appliance 100 can comply with the safety requirements—particular electrical safety requirements—of UL 471 for Commercial Refrigerators and Freezers.

[0097] Across at least a portion of the roof duct 206, a return divider or second divider 940 of the rail 120 and, more generally, the appliance 100 can separate the communication air cavity 938 from a return air cavity 948 and can thereby discourage or prevent “short cycling” of air that has circulated into and out of the pan storage cavity 428 through the rail duct 205. Instead, such air can be directed by the second divider 940 towards the one or more cabinet fan assemblies 207. Depending on the cooling needs of the base 110 and the base cavity 218, the air can then circulate through the base cavity 218 and can then return to the evaporator cavity 980, or the air can bypass the base cavity 218 and return directly to the evaporator cavity 980. A conduit or wire chase 950 can house at least a portion of wiring extending from the cabinet fan assemblies 207 to the controls system 170 (shown in FIG. 3) and through the base cavity 218. More specifically, the conduit 950 can define a closed shape after assembly and can define one or more panels, which can be angled with respect to each other.

[0098] The second divider 940 can extend partly across the roof duct 206 in the longitudinal direction 403 and, more generally, the cabinet 105, to reduce or prevent short cycling air that has already passed through the pan storage cavity 328 (shown in FIG. 9B) and is on its way toward the base cavity 218. In some aspects, more specifically, the second divider 940 can extend up to the first cabinet fan assembly 207 to ensure that air that has already passed through the pan storage cavity 428 closer to the evaporator cavity 980 is available to the cabinet fan assembly 207 closest to the evaporator cavity 980. In some aspects, one or more supplemental dividers 940a, b can be shaped similarly as the second divider 940 and can be secure a portion of the roof duct 206 to at least one of the interior surfaces 211,221. Between the one or more supplemental dividers 940a, b and between the one or more supplemental dividers 940a, b and the second divider 940, air can freely flow from the communication air cavity 938 to the return air cavity 948. Various fasteners (not shown) can assemble the dividers 930,940 to surrounding structures such as the roof duct 206. In some aspects, the dividers 930,940 can be welded (e.g., with spot welds) to the roof duct 206. In some aspects, a strip of insulation or a gasket material can be positioned on top of either of the dividers 930,940 and the mating structure to reduce or prevent air leakage through the connection.

[0099] FIG. 10 is a bottom perspective view of the cabinet fan assembly 207 of the appliance of FIG. 1. The cabinet fan assembly 207 can comprise the cabinet fan 1010. The cabinet fan 1010 can feed cold rail air through a cabinet fan enclosure 1020, which can evenly distribute air into the base cavity 218. More specifically, the cabinet fan 1010 can feed cold rail air through one or more openings 1028 defined in the cabinet fan enclosure 1020. The one or more openings 1028 can be distributed across one or more walls of the cabinet fan enclosure 1020. In some aspects, the cabinet fan enclosure 1020 can comprise a bottom wall 1023, a rear wall 1024 (shown in FIG. 11), side walls 1025, a front wall 1026, and one or more mounting flanges (not shown). As shown, a single opening 1028 can be defined in the bottom wall 1023. The cabinet fan assembly 207 can comprise a fan grill 1060, which can permit substantial air flow through the opening 1028 but prevent access by a user and can prevent physical objects from interfering with the rotation of the cabinet fan 1010. The cabinet fan assembly 207 can comprise the conduit 950, which can permit passage of electrical wires to the cabinet fan 1010 from a power source elsewhere on the appliance 100 but prevent access by the user and / or the other physical objects.

[0100] The cabinet fan 1010 can be an axial fan in which an air flow direction is parallel to an axis of rotation. The cabinet fan 1010 can define an air inlet or inlet (not shown) above the cabinet fan 1010, which can be configured to receive intake air in a direction parallel to an axis 1011 of the cabinet fan 1010, i.e., in an axial direction with respect to the axis 1011. The cabinet fan 1010 can define an air outlet or outlet 1014, which can be configured to expel exhaust air 1015 in a direction that is also parallel to the axis 1011, i.e., in a radial direction with respect to the axis 1011. In some aspects, the cabinet fan 1010 can be a blower fan in which the direction of air flow changes between the inlet and the outlet 1014.

[0101] The inlet of the cabinet fan 1010 can be aligned with the cabinet opening 1080 in the roof duct 206. In some aspects, as shown, the cabinet fan 1010 can be mounted to the cabinet fan enclosure 1020 and the cabinet fan enclosure 1020 can be secured to the roof duct 206. More specifically, one or more fasteners 1090 can extend through holes 1423 defined in the cabinet fan enclosure and can engage the roof duct 206 (e.g., with threaded inserts installed therein). In some aspects, the cabinet fan enclosure 1020 can further define an opening (not shown) for receipt of a lead wire connecting the cabinet fan 1010 to a cabinet fan relay or switch.

[0102] FIG. 11 is a detail sectional view of the appliance 100 of FIG. 1 taken from detail 11 of FIG. 5. As shown, the air that has already passed through the pan storage cavity 428 can also be freely received, as cooling needs dictate, into a cabinet opening 1080 defined in the roof duct 206 and through the cabinet fan 1010 of the cabinet fan assembly 207. The cabinet fan 1010 of each cabinet fan assembly 207 can be controlled by a separate thermostat such as a cabinet thermistor 1540 (shown in FIG. 10) in communication with the secondary controller 174 (shown in FIG. 1) or by a second temperature sensor (e.g., cabinet thermistor 1540) extending from the primary controller 172 (shown in FIG. 3).

[0103] As shown, the catch pan 260 can be received inside the worktop cavity 280 such that a surface of the catch pan 260 (e.g., a bottommost surface) is in contact with the interior surface 221 and, more specifically, the panel 521 of the worktop portion 202 of the rail 120. As such, a gap 1170 between an upper surface of the panel 521 and the nearest surface of the catch pan 260 can be zero, which can result in conduction of heat from the catch pan 260 into the panel 521, which can be cooled as described elsewhere herein. In some aspects, as shown, the portion of the catch pan 260 contacting the panel 521 can be planar, which can maximize the surface area in contact with the panel 521, which can also be planar.

[0104] A quantity of cabinet fans 1010 can vary based on the air flow needed through the cabinet fan assemblies 207. For example and without limitation, the one-section appliance 100 defining a width W (shown in FIG. 1) of 46 inches and the two-section appliance 100 defining a width W of 60 inches can comprise a single cabinet fan assembly 207 comprising a single cabinet fan 1010; and the two-section appliance 100 defining a width W of 67 inches and the three-section appliance 100 defining a width W of 93 inches can comprise a pair of cabinet fan assemblies 207, each comprising a cabinet fan 1010. Each of the cabinet fans 1010 can be sized based on the characteristics of the particular appliance 100 and the conditions of use but in some aspects as shown and tested can deliver at least or approximately 21 CFM. In some aspects, each of the cabinet fans 1010 can be a Model UF90DPB-series alternating current (AC) product measuring 120 mm square and 37 mm thick and available from Mechatronics Fan Group of Preston, Washington, U.S.A. In some aspects, as shown, one or more of the cabinet fans 1010 can be an axial fan of equivalent or greater capacity (e.g., CFM). Various fasteners (not shown) can assemble the components of the cabinet fan assemblies 207 together and to surrounding structures. On the unit shown, the cabinet fans 1010 can be positioned as shown. On a larger three-section unit measuring 93 inches wide, the cabinet fan 1010 can be positioned behind the divider 112 (shown in FIG. 2). In some aspects, the cabinet fan 1010 can be positioned symmetrically inside the base cavity 218. As shown, the cabinet fan 1010 can be positioned in front of the front wall 226 of the rail 120. As also shown, the cabinet fan 1010 can drive air into the base cavity 218 in a direction away from the main openings 118 and away from the closure devices 130 to reduce the risk of increased air leakage through the main openings 118.

[0105] Closer to a front of the appliance 100, a divider or shroud 1030 can separate the supply side 980a from the return side 980b of the evaporator cavity 980. In some aspects, a strip of insulation or a gasket material can be positioned on top of or around some or all of a perimeter of the shroud 1030 and between the shroud 1030 and the mating structure (e.g., one or more surfaces of the evaporator cavity 980 and / or the roof duct 206) to reduce or prevent air leakage through the connection.

[0106] The thermal break 219 can comprise one or more of several sealing structures including a bellows-style compressible portion, a rigid polymer extrusion and a compressible gasket. In some aspects, the various portions of the thermal break 219 can be formed integrally as a single component. In some aspects, the various portions of the thermal break 219 can be formed as separate components.

[0107] FIG. 12 is a top perspective partially cutaway view of a left end of a cabinet 105 of the appliance 100 of FIG. 1, and FIG. 13 is a top cutaway view of the return air opening of the left end of the cabinet 105 of FIG. 12, each with at least a portion of the worktop portion 202 of the rail 120 removed for clarity The roof duct 206 can define a return air opening 1380, which can allow passage of air from the return air cavity 948 to the evaporator cavity 980 and specifically the return side 980b thereof. In some aspects, the return air opening 1380 can define any polygonal or other closed shape. In some aspects, the return air opening 1380 can define a plurality of openings (e.g., slots), but fewer openings can facilitate less restriction to air flow.

[0108] A rail thermistor or rail sensor or sensor 1320, which can be a first control input or first sensor, can be mounted to the shroud 1030 in a mounting location 1325. The rail thermistor 1320 can come with the controller 172 and can be as specified from Danfoss A / S (e.g., Part No. 077 08767). In some aspects, the rail thermistor 1320 can be mounted to any other interior structure of the return air cavity 948 or the return side 980b of the evaporator cavity 980. In some aspects, the rail thermistor 1320 can be mounted with a wire tie (not shown), which can be configured to firmly hold the rail thermistor 1320 and prevent it from touching any surrounding metal or other interior surface. More specifically, a barbed attachment of a mounting portion of the wire tie can be received into a hole in the mounting surface, and a securing portion of the wire tie can receive and adjustably tighten around the rail thermistor 1320. For example and without limitation, the wire tie can be P / N PLT2D-M available from Vallen Distribution. The rail thermistor 1320 can be in electrical communication with the controller 172 (shown in FIG. 3).

[0109] The cabinet thermistor or cabinet sensor or control input or sensor 1540 (shown in FIG. 10), which can be a second control input or second sensor, can be mounted to an underside of the roof duct 206 in a mounting location 1345 (shown in FIG. 10). The cabinet thermistor 1540 can come with the secondary controller 174 (shown in FIG. 1) and can be as specified from Ascon Technologic S.r.L. (e.g., Part No. NTC-TPEGY-A1). In some aspects, the cabinet thermistor 1540 can be mounted to any other interior structure of the base cavity 218 that will not interfere with operation of the appliance 100. In some aspects, the cabinet thermistor 1540 can be mounted with a wire tie configured to firmly hold the cabinet thermistor 1540 and prevent it from touching any surrounding metal or other interior surface. More specifically, a barbed attachment of a mounting portion of the wire tie can be received into a hole in the mounting surface, and a securing portion of the wire tie can receive and adjustably tighten around the cabinet thermistor 1540. For example and without limitation, the wire tie can be a wire tie as noted above. The cabinet thermistor 1540 can be in electrical communication with the secondary controller 174 or, in the case of a single controller controlling both cabinet and rail air temperatures, the controller 172.

[0110] FIG. 14 is an exploded top right perspective view of the appliance 100 of FIG. 1 showing the catch pan 260 of FIG. 4D and associated parts, FIG. 15 is a sectional view of the appliance 100 of FIG. 1 taken along line 15-15 of FIG. 14, and FIG. 16 is a detail sectional view of the appliance 100 of FIG. 1 taken from detail 16 of FIG. 15. As shown, a portion of the worktop cavity 280 can be configured to receive the catch pan 260, the cover 270, and / or the worktop support 250. As shown, each of the catch pan 260, the cover 270, and / or the worktop support 250 can be removable through a top of the worktop opening 280. Each of the catch pan 260 and the cover 270 can be sized and otherwise configured to be received within the worktop cavity 280.

[0111] As shown in FIG. 16, the worktop support 250 can be sized and otherwise configured to be received within a larger workspace available above the worktop cavity 280 and in some aspects extending even past a front nose of the appliance 100. More specifically, as described above, the support bracket 420 can support a portion of the worktop support 250 in the vertical (up-down) and horizontal (front-rear) directions of the appliance 100. As shown, the support bracket 420 can have or define a “Z” shape in cross-section, which can comprise a first vertical portion 422, a horizontal portion 424, and a second vertical portion 426. For example and without limitation, the first vertical portion 422 can be securable to the rail 120, the horizontal portion 424 can support a lower end or side of the worktop support 250, and the second vertical portion 426 can restrain a front end or side of the worktop support 250. As shown, a catch guard 1650 can be secured to the worktop support 250 and prevent spillage of food ingredients past a front edge of the appliance 100. More specifically, the catch guard 1650 can have or define a “Z” shape in cross-section. More specifically, the catch guard can comprise a first vertical portion 1652, a horizontal portion 1654, and a second vertical portion 1656. For example and without limitation, the first vertical portion 1652 can be securable to the worktop support 250 by being restrained against a vertical surface of the worktop support 250, the horizontal portion 1654 can be supported by an upper end or side of the worktop support 250, and the second vertical portion 1656 can restrain or limit movement or “catch” ingredients that might otherwise fall off the front edge of the rail 120 and, more generally, the appliance 100.

[0112] FIG. 17 is a top perspective view of the catch pan 260 of FIG. 4D, and FIG. 18 is a bottom perspective view of the catch pan 260 of FIG. 4D. The catch pan 260 can comprise a main panel 1710. The main panel 1710 can define four ends. The catch pan 260 can comprise one or more first flanges or flanges 1720, each of or any of which can extend from the main panel 1710. More specifically, each of or any of the one or more first flanges 1720 can be angled with respect to the main panel 1710 and can thereby form a wall, which can define a height of the catch pan 260. The catch pan can comprise one or more second flanges or flanges 1730, each of or any of which can extend from one of the corresponding first flanges 1720. More specifically, each of or any of the one or more second flanges 1730 can be angled with respect to one of the corresponding first flanges 1720. The catch pan 260 can comprise a handle 1750, which can be releasably secured to a remaining portion of the catch pan 260 and, more specifically, the main panel 1710 with one or more fasteners 1759. Each of or any of corners at which the first flanges 1720 and / or the second flanges 1730 intersect or approximately join can comprise a weldment or other fastening structure 1790. By attaching a single handle 1750 to the catch pan 260, a force to remove the catch pan 260 can be centered and removal can be facilitated.

[0113] FIG. 19 is a top perspective view of the cover 270 of FIG. 4E, and FIG. 20 is a bottom perspective view of the cover 270 of FIG. 4E. The catch pan 260 can comprise a main panel 1910. The main panel 1910 can define four ends. The catch pan 260 can comprise one or more first flanges or flanges 1920, each of or any of which can extend from the main panel 1910. More specifically, each of or any of the one or more first flanges 1920 can be angled with respect to the main panel 1910. The catch pan can comprise one or more second flanges or flanges 1930, each of or any of which can extend from one of the corresponding first flanges 1920. More specifically, each of or any of the one or more second flanges 1930 can be angled with respect to one of the corresponding first flanges 1920. In some aspects, as shown, each of the second flanges 1930 can be or comprise a hem, which can ease installation of the cover 270 and / or further reinforce the cover 270. The catch pan 260 can comprise a handle 1950, which can be releasably secured to a remaining portion of the catch pan 260 and, more specifically, the main panel 1910 with one or more fasteners 1959. Each of or any of corners at which the first flanges 1920 and / or the second flanges 1930 intersect or approximately join can comprise a weldment or other fastening structure 1990. By attaching a pair of handles 1950 to the cover 270, one of the handles 1950 can be made accessible to a user while the cover 270 is stored inside an upper portion of the rail 120 (e.g., the third portion 126). The cover 270, which can be made flush with the surrounding surface of the thermal break 450 and / or the worktop portion 202, can facilitate overnight operation of the appliance 100 with minimal heat transfer into the appliance 100 through the worktop cavity 280.

[0114] FIG. 21 is a top plan view of the appliance 100 of FIG. 1. In some aspects, as shown, an overall width of the worktop opening 280 can be divided into equal parts as an effective catch pan width 2180. In some aspects, the catch pan 260 and the dimensions of the worktop cavity 280 can be as desired by a user. A width 2170 of a side of the worktop portion 202 surrounding the worktop cavity 280 (and similarly, a width of a front or rear of the worktop portion 202) can be sized to facilitate the flow of foam insulation and to facilitate a seal between the rail 120 and the base 110.

[0115] FIG. 22 is a detail top perspective view of the worktop cavity 280 of the appliance 100 of FIG. 1 showing the thermal breaker or thermal break 450 defining a perimeter of the worktop cavity 280, and FIG. 23 is a detail sectional view of the worktop portion 202 of the appliance of FIG. 1 taken from line 23 -23 of FIG. 22 and showing a cross-section of the thermal break 450. The thermal break 450 can extend from the panel 521 to the upper or outer panel of the worktop portion 202 of the rail 120. The thermal break 450 can define a shoulder 2215, which can support the catch pan 260 and, more specifically, the second flanges 1730 thereof. A width of the shoulder 2215 can facilitate sealing of a gap between the catch pan 260 and the thermal break 450 by extending a distance along which air must travel to escape from an area between the catch pan 260 and the thermal break 450. Separate pieces of the thermal break can be joined at a miter joint, with or without welding. In some aspects, a frame formed by portions of the thermal break 450 can be preassembled and dropped into a surrounding structure of the rail 120. As with other cavities formed by the various inner and outer panels of the rail 120 and the base 110, foam can be injected inside as insulation to increase resistance against heat transfer into the appliance 100 from an ambient environment.

[0116] FIG. 24 is a detail top perspective view of the appliance 100 of FIG. 1 showing the catch pan 260 of FIG. 4D overlapping with an adjacent catch pan 260 by an overlap distance 2470. In some aspects, the catch pans 260 and the dimensions of the worktop cavity 280 can be sized to produce such overlap, i.e., an average overlap distance greater than zero, in order to reduce gaps from which cold can escape from—or heat can be absorbed by—the worktop opening 280. The overlap distance 2470 can be measured between edges of the second flanges 1730.

[0117] A method of using the appliance 100 can comprise distributing air through an air plenum system of the appliance 100 and, more specifically, throughout the pan storage cavity 428 and around the pans 510 to maintain proper temperatures of food product stored therein. More specifically, the method can comprise complying with NSF / ANSI Standard 7 performance requirements in an ambient temperature of 86° F. (30° C.). The method can comprise complying with NSF / ANSI Standard 7 pan temperature requirements in an ambient temperature of 100° F. (37.8° C.). The method need not comprise distributing refrigerant as is typical in the aforementioned “cold-wall” design. The method can comprise properly maintaining air and product temperatures throughout the first refrigerated portion 101. The method can comprise cooling a first refrigerated portion 101 and a second refrigerated portion 102 with only a single refrigeration system 150 comprising only a single evaporator 670. The method can comprise regulating a temperature of the base cavity 218 with one or more cabinet fans 1010 only as needed based on input from a sensor such as the cabinet thermistor 1540.

[0118] A method of distributing air can comprise moving refrigerated air from an evaporator cavity 980 to the intake air cavity 910. The method can comprise moving air through the intake air cavity 910 in the longitudinal direction 403 along a length of the rail 120. The method can comprise directing air inside the intake air cavity 910 towards the rear wall 224 of the rail 120 and up between the rear wall 424 of the rail duct 205 and the rear wall 224 of the rail 120. The method can comprise moving air through the openings 480a such as, for example and without limitation, one or more of the air transmission openings 482a, the handle openings 484a, and the supplemental openings 486a. The method can comprise moving air, in one or more corners of the rail 120, through the openings 480b such as, for example and without limitation, other supplemental openings. The method can comprise pressurizing air from the evaporator cavity 980 and thereby distributing air throughout the first refrigerated compartment 103. The method can comprise circulating air through the pan storage cavity 428 and around the plurality of pans 510 positioned therein. In some aspects, as shown, the method can comprise moving air from the rear of the rail 120 to the front of the rail 120 (i.e., front-to-back). In some aspects, by reconfiguring the rail duct 205 and the roof duct 206 the method can comprise moving air from the front of the rail 120 to the rear of the rail 120. The method can comprise moving air through the openings 480b and into the communication air cavity 938 in a direction towards the base cavity 218.

[0119] The method can comprise moving air from the pan storage cavity 428 to the communication air cavity 938. As such, the method can comprise moving air around an obstacle (e.g., the second divider 940) separating the communication air cavity 938 and the return air cavity 948 for a sufficient distance to discourage or prevent short cycling of air back to the evaporator cavity 980 before reaching the base cavity 218. The method can comprise moving air towards the one or more cabinet fan assemblies 207 in a direction parallel to the obstacle.

[0120] When the base cavity 218 does not require further cooling, the method can comprise bypassing the base cavity 218, i.e., returning some or all of the air directly to the evaporator cavity 980 without going through the base cavity 218. When the base cavity 218 does require further cooling, the method can comprise circulating the air through the base cavity 218 and then can comprise returning the air to the evaporator cavity 980.

[0121] More specifically, the method can comprise moving air through the cabinet opening 1080 defined in the roof duct 206 and through the cabinet fan 1010 of the cabinet fan assembly 207. The method can comprise controlling the cabinet fan 1010 by a separate thermostat, e.g., the cabinet thermistor 1540, of the secondary controller 174 or by a second temperature sensor extending from the primary controller 172. The method can comprise moving air through the cabinet fan enclosure 1020, which can evenly distribute air into the base cavity 218. The method can comprise moving air through the openings 1028 defined in the cabinet fan enclosure 1020. The method can comprise moving air into the base cavity 218 in a direction away from the main openings 118 and away from the closure devices 130 to reduce the risk of increased air leakage through the main openings 118. The method can comprise moving air from the base cavity 218 to the evaporator cavity 980. The method can comprise moving air from the base cavity 218 to the return side 980b of the evaporator cavity 980 through the return air opening 1380, which can be defined in a lower surface of the roof duct 206.

[0122] The method can comprise regulating a temperature of air circulating through the rail cavity 228 between the intake air cavity 910 and the return air cavity 948 with the rail thermistor 1320, which again can be mounted inside the return side 980b of the evaporator cavity 980. The method can comprise regulating a temperature of air circulating through the base cavity 218 with the cabinet thermistor 1540, which again can be mounted inside the base cavity 218.

[0123] The method can comprise receiving the intake air 1413 into an inlet 1412 of cabinet fan 1010 along the axis 1411 of the cabinet fan 1010 and expel exhaust air 1415 in a direction perpendicular to the axis 1411. Thus the method can comprise changing the direction of air flow between the inlet 1412 and the outlet 1414. In some aspects, the method can comprise drawing air from inside the roof duct 206 and directing such air into and through an air distribution duct 1520 that is separate from the cabinet fan enclosure 1020.

[0124] The method can comprise cooling the ceiling of the base 110, which can comprise simultaneously cooling an interior surface 221 of the rail and, more specifically, a panel 521 defining the interior surface 221. The method can comprise inserting the catch pan 260 into the worktop cavity 280, which can comprise contacting the panel 521 with a portion of the catch pan 260 and, more specifically, a bottommost surface or main panel 1710 of the catch pan 260. More specifically, the method can comprise cooling the catch pan 260 by conduction and thereby regulating a temperature of food ingredients caught therein during use of the appliance 100. The method can comprise not blowing air over the catch pans, which can dry the food ingredients.

[0125] In some aspects, various components of the appliance 100 can be formed from or comprise a metal such as, for example and without limitation, steel. More specifically, components exposed to food and / or liquids including cleaning fluids including the user-facing surfaces of the appliance can be formed from or comprise stainless steel. Materials configured to insulate against heat transfer (e.g., the thermal break 219) and / or flex (e.g., door / drawer gaskets and an interior panel of the doors) can be formed from or comprise a polymer material such as polyvinyl chloride (PVC) or acrylonitrile butadiene styrene (ABS). In some aspects, the various components can be formed from any other material, any of which can optionally be corrosion-resistant or replaceable for serviceability.

[0126] The various components of the appliance 100 can be formed from any one or more of a variety of manufacturing processes. For example and without limitation, the rail duct 205, the roof duct 206, and various other components of the air plenum system of the appliance 100 can be fabricated using subtractive manufacturing processes such as cutting and stamping. In some aspects, components can be made using machining and / or forging; additive manufacturing processes such as three-dimensional printing; and any other forming and assembly processes such as bending and riveting.

[0127] One should note that conditional language, such as, among others, “can,”“could,”“might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain aspects include, while other aspects do not include, certain features, elements and / or steps. Thus, such conditional language is not generally intended to imply that features, elements and / or steps are in any way required for one or more particular aspects or that one or more particular aspects necessarily comprise logic for deciding, with or without user input or prompting, whether these features, elements and / or steps are included or are to be performed in any particular aspect.

[0128] It should be emphasized that the above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Any process descriptions or blocks in flow diagrams should be understood as representing modules, segments, or portions of code which comprise one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included in which functions may not be included or executed at all, may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present disclosure. Many variations and modifications may be made to the above-described aspect(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.

Examples

Embodiment Construction

[0039]The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, and / or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and / or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0040]The following description is provided as an enabling teaching of the present devices, systems, and / or methods in their best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects described herein, while still obtaining the beneficial results of the present disclosure. It will also ...

REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 762,630, filed Feb. 24, 2025, which is hereby specifically incorporated by reference herein in its entirety. This application also specifically incorporates by reference herein in its entirety U.S. application Ser. No. 17 / 889,246, filed on Aug. 16, 2022, and entitled REFRIGERATED APPLIANCE WITH DUCTED AIR FLOW; and U.S. application Ser. No. 17 / 889,249, filed on Aug. 16, 2022, and entitled REFRIGERATED APPLIANCE WITH AUTOMATICALLY ADJUSTABLE SETPOINT.TECHNICAL FIELDField of Use

[0002] This disclosure relates to refrigerated appliances. More specifically, this disclosure relates to refrigerated appliances with a refrigerated rail and refrigerated lower cabinet and refrigerated catch pans cooled by air circulated through an air plenum system.Related Art

[0003] A refrigerated appliance comprising an open, refrigerated rail is common and useful in a kitchen. Able to store at refrigerated temperatures a large variety of food ingredients used in food preparation such as the making of pizzas and sandwiches, such appliances can significantly improve user convenience and efficiency. The food ingredients stored in the open rail are not uncommonly placed on prepared food dishes (e.g., a pizza) in such a way that some of the ingredients fall into an area of the counter under and / or around the prepared dishes. Even where a structure for collecting such food product is present, the structure is not typically able to maintain the food product at sufficiently cool temperatures, meaning the collected food may not be able to be reused, or the structure is expensive, cumbersome, and / or prone to failure.SUMMARY

[0004] It is to be understood that this summary is not an extensive overview of the disclosure. This summary is exemplary and not restrictive, and it is intended to neither identify key or critical elements of the disclosure nor delineate the scope thereof. The sole purpose of this summary is to explain and exemplify certain concepts of the disclosure as an introduction to the following complete and extensive detailed description.

[0005] In one aspect, disclosed is a refrigerated appliance comprising: a refrigeration system, an evaporating unit thereof configured to supply air to an air plenum system of the appliance, the air plenum system configured to cool the appliance; a cabinet defining the air plenum system, the cabinet comprising: a first refrigerated portion defining a pan storage cavity configured to receive at least one food pan; a second refrigerated portion positioned below the first refrigerated portion and comprising; an insulated enclosure defining an interior surface and a base cavity configured to receive stored product; a duct received within the insulated enclosure and defining, at least in part, a communication air cavity, the communication air cavity being in fluid communication with each of the pan storage cavity and a return air cavity, the return air cavity being in fluid communication with the evaporating unit; and a worktop cavity defined in a worktop defined by the cabinet, the worktop defining at least in part the second refrigerated portion, the worktop cavity configured to receive a catch pan, the catch pan configured to be cooled by air inside the insulated enclosure.

[0006] In a further aspect, disclosed is a method of using a refrigerated appliance comprising: inserting a catch pan into a rail comprising a worktop portion and a rail portion, the catch pan received within a worktop cavity defined within the worktop portion; and cooling the catch pan through cooling of an interior cavity of the appliance.

[0007] Various implementations described in the present disclosure may comprise additional systems, methods, features, and advantages, which may not necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims. The features and advantages of such implementations may be realized and obtained by means of the systems, methods, features particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims or may be learned by the practice of such exemplary implementations as set forth hereinafter.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the disclosure and together with the description, serve to explain various principles of the disclosure. The drawings are not necessarily drawn to scale. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity.

[0009] FIG. 1 is a top right perspective view of a two-section refrigerated preparation table appliance with a raised rail in accordance with one aspect of the current disclosure.

[0010] FIG. 2 is a top front left perspective view of a lower left portion of the appliance of FIG. 1.

[0011] FIG. 3 is a partially exploded rear perspective view of the lower left portion of the appliance of FIG. 1 showing various access panels removed and offset from the appliance.

[0012] FIG. 4A is a top front perspective view of the appliance of FIG. 1.

[0013] FIG. 4B is a detail top front perspective view of the appliance of FIG. 1.

[0014] FIG. 4C is a detail top front perspective view of a right end of a worktop portion of the appliance of FIG. 1 with a worktop support in place.

[0015] FIG. 4D is a detail top front perspective view of a right end of the worktop portion of the appliance of FIG. 1 with a portion of the worktop support removed and showing a catch pan received within the worktop portion.

[0016] FIG. 4E is a detail top front perspective view of a right end of the worktop portion of the appliance of FIG. 1 with a portion of the worktop support removed and showing a cover received within the worktop portion.

[0017] FIG. 5 is a sectional view of the appliance of FIG. 1 taken along line 5-5 of FIG. 1.

[0018] FIG. 6A is a schematic view of a refrigeration system of the appliance of FIG. 1.

[0019] FIG. 6B is a perspective view of the refrigeration system of FIG. 6A.

[0020] FIG. 7 is a schematic view of an airflow circuit of the appliance of FIG. 1.

[0021] FIG. 8 is a detail front perspective view of a left side of a cabinet base of the appliance of FIG. 1 showing a primary controller configured to control an air temperature of the rail and a secondary controller configured to control an air temperature of an interior cavity of the cabinet.

[0022] FIG. 9A is a sectional view of the appliance of FIG. 1 taken along line 9A-9A of FIG. 5.

[0023] FIG. 9B is a detail sectional view of the appliance of FIG. 1 taken along line 9B-9B of FIG. 9A in accordance with another aspect of the current disclosure and showing only geometry in the cut plane.

[0024] FIG. 10 is a bottom perspective view of a cabinet fan assembly of the appliance of FIG. 1.

[0025] FIG. 11 is a detail sectional view of the appliance of FIG. 1 taken from detail 11 of FIG. 5.

[0026] FIG. 12 is a top perspective partially cutaway view of a left end of a cabinet of the appliance of FIG. 1 with a portion of worktop portion of the rail removed for clarity.

[0027] FIG. 13 is a top cutaway view of the return air opening of the left end of the cabinet of FIG. 12 with at least a portion of the worktop portion of the rail removed for clarity.

[0028] FIG. 14 is an exploded top right perspective view of the appliance of FIG. 1 showing the catch pan of FIG. 4D and associated parts.

[0029] FIG. 15 is a sectional view of the appliance of FIG. 1 taken along line 15-15 of FIG. 14.

[0030] FIG. 16 is a detail sectional view of the appliance of FIG. 1 taken from detail 16 of FIG. 15.

[0031] FIG. 17 is a top perspective view of the catch pan of FIG. 4D.

[0032] FIG. 18 is a bottom perspective view of the catch pan of FIG. 4D.

[0033] FIG. 19 is a top perspective view of the cover of FIG. 4E.

[0034] FIG. 20 is a bottom perspective view of the cover of FIG. 4E.

[0035] FIG. 21 is a top plan view of the appliance of FIG. 1.

[0036] FIG. 22 is a detail top perspective view of the worktop cavity of the appliance of FIG. 1 showing a thermal break defining a perimeter of the worktop cavity.

[0037] FIG. 23 is a sectional view of the worktop portion of the appliance of FIG. 1 taken from line 23-23 of FIG. 22.

[0038] FIG. 24 is a detail top perspective view of the appliance of FIG. 1 showing the catch pan of FIG. 4D overlapping with an adjacent catch pan.DETAILED DESCRIPTION

[0039] The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, and / or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and / or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0040] The following description is provided as an enabling teaching of the present devices, systems, and / or methods in their best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects described herein, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

[0041] As used throughout, the singular forms “a,”“an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a quantity of one of a particular element can comprise two or more such elements unless the context indicates otherwise. In addition, any of the elements described herein can be a first such element, a second such element, and so forth (e.g., a first widget and a second widget, even if only a “widget” is referenced).

[0042] Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another aspect comprises from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about” or “substantially,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0043] For purposes of the current disclosure, a material property or dimension measuring about X or substantially X on a particular measurement scale measures within a range between X plus an industry-standard upper tolerance for the specified measurement and X minus an industry-standard lower tolerance for the specified measurement. Because tolerances can vary between different materials, processes and between different models, the tolerance for a particular measurement of a particular component can fall within a range of tolerances.

[0044] As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description comprises instances where said event or circumstance occurs and instances where it does not.

[0045] The word “or” as used herein means any one member of a particular list and also comprises any combination of members of that list. The phrase “at least one of A and B” as used herein means “only A, only B, or both A and B”; while the phrase “one of A and B” means “A or B.”

[0046] As used herein, unless the context clearly dictates otherwise, the term “monolithic” in the description of a component means that the component is formed as a singular component that constitutes a single material without joints or seams except those resulting by re-shaping of the material.

[0047] To simplify the description of various elements disclosed herein, the conventions of “left,”“right,”“front,”“rear,”“top,”“bottom,”“upper,”“lower,”“inside,”“outside,”“inboard,”“outboard,”“horizontal,” and / or “vertical” may be referenced. Unless stated otherwise, “front” describes that end of the appliance nearest to and occupied by a user of the appliance; “rear” is that end of the appliance that is opposite or distal the front; “left” is that which is to the left of or facing left from a person standing in front of the appliance and facing towards the front; and “right” is that which is to the right of or facing right from that same person. “Horizontal” or “horizontal orientation” describes that which is in a plane extending from left to right and aligned with the horizon. “Vertical” or “vertical orientation” describes that which is in a plane that is angled at 90 degrees to the horizontal.

[0048] In one aspect, a refrigerated appliance and associated methods, systems, devices, and various apparatuses are disclosed herein. In one aspect, the refrigerated appliance can comprise a first refrigerated portion comprising a first refrigerated compartment and a second refrigerated portion comprising a second refrigerated compartment. The refrigerated appliance can further comprise a refrigerated catch pan.

[0049] Maintaining food product at proper temperatures in a refrigerated appliance can be challenging, especially during industry-standard (e.g., NSF / ANSI Standard 7) test conditions that require maintenance of both rail temperatures (i.e., temperatures of special simulated food material stored in pans positioned in the rail) and cabinet temperatures within proper ranges, e.g., 0.6° C. to 5.0° C. for the rail box car average temperatures using the special simulated food material and 0° C. to 4.4° C. for the lagged cabinet temperatures. Because of the harsh environment found in a commercial kitchen in which many appliances are used, these temperatures must usually be maintained with the appliance in an ambient environment defining an ambient temperature that is usually higher than typical room temperature. For example, NSF / ANSI Standard 7 test conditions typically require an ambient temperature during testing of 86° F., but some actual use conditions can reach up to around 100° F. on the warm end or down to around 45° F. on the cold end. Cooling with expensively manufactured cabinets in which refrigerant or a eutectic fluid (e.g., a liquid having similar properties to anti-freeze liquid used in motor vehicle) circulates through the walls is not a practical or cost-effective option for some users.

[0050] In addition, a typical appliance comprising a raised rail typically also comprises a rail cover for hygienic and other reasons. Because closing the cover can significantly lower the temperature of the rail and users are either not able to or accustomed to manually make the adjustments necessary to avoid freezing of product, which can result in spoilage, users often remove food product from the rail and store elsewhere whenever the appliance and / or the rail will be unattended for more than a short period (e.g., overnight). One or more of the challenges associated with these and other issues can be solved by the structures and methods disclosed herein.

[0051] FIG. 1 is a perspective view of a refrigerated appliance 100 in accordance with one aspect of the current disclosure. The appliance 100 can comprise a cabinet body or base 110 and a rail body or rail 120. The base 110 and the rail 120 can together form a cabinet 105 of the appliance 100. The rail 120 can extend or protrude vertically from and above the base 110. In some aspects, the rail 120 can extend the full length of the base 110. In some aspects, the rail 120 can extend only partially across the base 110. The appliance 100 and, more specifically, the base 110 thereof can comprise one or more closure devices 130. In some aspects, as shown, the closure device 130 can be or can comprise a door, which can be hinged on one side or another of the closure device 130. More specifically, a handle 135 attached to or defined in the closure device 130 can facilitate opening of the closure device 130. Similarly, the appliance 100 and, more specifically, the rail 120 thereof can comprise one or more closure devices 140. In some aspects, as shown, the closure device 140 can be or can comprise a cover or lid, which can be hinged on one side or another of the closure device 130. More specifically, a handle 145 attached to or defined in the closure device 140 can facilitate opening of the closure device 140. The closure device 140 and the closure device 130 can be oriented in different planes.

[0052] In some aspects, as shown, the rail 120 can comprise multiple portions, which can be separably assembled to each other. The rail 120 can comprise a first portion 122, which can define the first refrigerated portion 101 and, more specifically, an opening 208 (shown in FIG. 4A) and the pan storage cavity 528 (shown in FIG. 5). The rail 120 can comprise a second portion 124, which can comprise one or more walls 125 extending from and / or past the first portion 122. The walls 125 can extend in a vertical or substantially vertical direction. The second portion 124 can shield the first portion 122 from convective heat transfer from the surrounding ambient air into pans 510 (shown in FIG. 5) stored in the pan storage cavity 528. The rail 120 can comprise a third portion 126, which can comprise one or more walls 127 and / or extending from and / or past the first portion 122 and / or the second portion 124. Like the second portion 124, the third portion 126 can shield the first portion 122 from convective heat transfer from the surrounding ambient air into pans 510 (shown in FIG. 5) stored in the pan storage cavity 528. The third portion 126 can additionally comprise walls 129. The walls 129 can extend in a horizontal or substantially horizontal direction. One or more of the walls 129 can define one or more storage cavities 128, which can be sized and otherwise configured to receive and, more specifically, slideably receive one or more worktop supports 250, one or more catch pans 260, and / or one or more covers 270. In some aspects, as shown, the storage cavities 128 can be sized and otherwise configured to receive each of the covers 270. In some aspects, the first portion 122, the second portion 124, and / or the third portion 126 can define a polygonal shape in cross-section.

[0053] The appliance 100 can comprise a refrigeration circuit or refrigeration system 150 (shown in FIG. 3), which can be housed within a portion of the base 110 and, more specifically, a cavity defined therein. Access panels 160 such as, for example and without limitation, one or more of a front access panel 162, a side access panel 164 (shown in FIG. 3), and a rear access panel 166 (shown in FIG. 3) can selectively provide or block access to the refrigeration system 150 and / or other components of the appliance 100 to which a user need not have immediate access. In some aspects, as shown, the base 110 can be supported by a plurality of supports 190 (shown in FIG. 2), which can be wheels or casters by which the appliance 100 can be rolled from one location to another. In some aspects, the supports 190 can comprise one or more legs. More generally, the appliance 100 can define one or more “sections” in which each section can define a main opening 118, which the one or more closure devices 130 can be configured to selectively cover. More specifically, each of the closure devices 130,140 can be configured to limit leakage of air from an ambient environment to and from the base 110 or the rail 120 or any portion thereof. In some aspects, the opening 208 of the rail 120 or a portion thereof and the opening 118 of the base 110 or a portion thereof can face in different directions. More specifically, the opening 208 can face generally upward, and the opening 118 of the base 110 can face generally forward. In some aspects, as shown, the appliance 100 can be a two-section refrigerated preparation table. In other aspects, the appliance 100 can comprise or define any number of sections.

[0054] The sections or the openings 118 defined therein can be positioned adjacent to each other with a frame, mullion, or divider 112 positioned therebetween. The divider 112 can extend in a vertical direction and can be insulated. More specifically, the divider 112 or any similar structure can encapsulate an insulating material such as blown or block foam. The divider 112 can be heated to reduce or eliminate condensation that might otherwise form on an outer surface thereof because the appliance 100 is refrigerated. As disclosed herein, “refrigerated” means broadly that which is cooled or that which cools or keeps cool, whether the temperature of the cooled space, cooled product, or other disclosed elements are above or below 32° F., the freezing point of water. In some aspects, as shown, the closure device 130 can be or can comprise a drawer or a set of drawers, which be supported inside a drawer frame secured to the base 110. Such a drawer frame or equivalent structure can comprise a frame, mullion, or divider 114, which can be positioned between adjacent drawers. In some aspects, as shown, the closure device 140 can be or can comprise a rail cover or lid. In some aspects, the closure device 140 can be or can comprise more than one rail cover or lid.

[0055] The appliance 100 can define a width W measured in a direction parallel with a front of the appliance 100. The appliance 100 can define a depth D measured in a direction parallel with a side of the appliance 100. The appliance 100 can define a height H measured in a vertical direction of the appliance 100. In some aspects, the appliance 100 can define an internal volume of a cabinet or base cavity 218, which can measure between 11 cubic feet and 30 cubic feet. In some aspects, the internal volume of the base cavity 218 can be outside of this range.

[0056] The appliance 100 can comprise a controls system 170, which in some aspects can comprise a primary controller or controller 172 (shown in FIG. 3) and a secondary controller 174. The primary controller 172 can be configured to control overall operation of the appliance 100 and, more specifically, cooling of the rail 120. Meanwhile, the secondary controller 174 can be configured to control cooling of the base 110. As shown, the secondary controller 174, which can comprise a control interface 175, can be secured to the front access panel 162. In some aspects, as will also be described herein, a single controller 172 of the controls system 170 can control all aspects of cooling of the appliance 100.

[0057] FIGS. 2 and 3 are various views of a lower left portion of the appliance 100 of FIG. 1. FIG. 2 is a top front left perspective view of a lower left portion of the appliance 100, and FIG. 3 is a partially exploded rear perspective view of the lower left portion of the appliance 100 showing various access panels 160 removed and offset from the appliance 100. Again, the access panels 160 can comprise one or more of the front access panel 162, the side access panel 164, and the rear access panel 166, which are shown removed and offset from the appliance 100. One or more of the access panels 160 can define openings 168, which can facilitate ventilation of, i.e., circulation of air to and from, the refrigeration system 150. The appliance 100 can comprise a power cord 70, which can be configured to supply power to the appliance 100 overall, including the refrigeration system 150. The appliance 100 can comprise the controller 172, which can again be a primary controller and can be configured to control overall operation of the appliance 100 including operation of the refrigeration system 150.

[0058] FIGS. 4A-4E are various views of the appliance 100 of FIG. 1. FIG. 4A is a top front perspective view of the appliance of FIG. 1. The rail 120 can comprise a worktop portion 202 and a rail portion 203. Again, as also shown, the appliance 100 can comprise one or more of the worktop supports 250, upon which a user can cut, assemble, and / or otherwise process a product (e.g., food ingredients for use in preparing a pizza, sandwich, or other food product). In some aspects, the work surface and, more specifically, the one or more worktop supports 250 can be defined by one or more grates or grills, each of which can be formed from or comprise wire and, more specifically, metal wire welded into a frame. The one or more worktop supports 250 can be secured to or otherwise restrained to a certain position on the rail 120 and, more specifically, the worktop portion 202 with brackets 255. More specifically, as shown, each of the brackets 255 can restrain movement of the one or more worktop supports 250 in a lateral or left-to-right direction of the appliance 100.

[0059] FIG. 4B is a detail top front perspective view of the appliance 100 of FIG. 1, FIG. 4C is a detail top front perspective view of a right end of the worktop portion 202 of the appliance 100 of FIG. 1 with the worktop support 250 in place, and FIG. 4D is a detail top front perspective view of a right end of the worktop portion 202 of the appliance 100 of FIG. 1 with a portion of one of the worktop supports 250 removed. The worktop portion 202 can comprise a worktop body 210 and a worktop cavity 280, which can be a recess defined in the worktop body 210. The appliance 100 can comprise the catch pan 260, which can be received within the worktop cavity 280. The catch pan 260 can be configured to catch or collect food ingredients that drop through the worktop support 250 during use of the appliance 100. By catching and maintaining a temperature of the food ingredients, the food ingredients can be returned to the rail and / or otherwise reused, which can reduce waste and thereby operational costs. The worktop portion 202 can further comprise a support bracket 420, which can be secured to a front edge of a surrounding or remaining portion of the worktop portion 202 and can extend past a remaining portion of the front edge of the worktop portion 202 and can provide additional support for the one or more worktop supports 250.

[0060] FIG. 4E is a detail top front perspective view of a right end of the worktop portion 202 of the appliance 100 of FIG. 1 with a portion of the worktop support 250 removed and showing the plug or cover 270, which can be received within the worktop portion 202. The cover 270 can sealably cover or otherwise cover the worktop cavity 280 and thereby can help maintain a temperature of the air inside the worktop cavity 280. The appliance 100 and, more specifically, the worktop portion 202 can comprise a thermal break 450, which can slow heat transfer into the rail 120. More specifically, the thermal break 450 can comprise or be formed from a non-thermally conductive material such as, for example and without limitation, a plastic or polymer resin.

[0061] FIG. 5 is a sectional view of the appliance 100 of FIG. 1 taken along line 5-5 of FIG. 1 showing the closure devices 130 (more specifically, a pair of drawers in a left section of the appliance 100) replaced with a door as the closure device 130 in the left section. One or more walls of each of the base 110 and the rail 120 can be insulated. For example and without limitation, the walls can be insulated with blown or block foam, which can be a polyurethane foam. Either or both of the closure devices 130,140 can be similarly insulated. The rail 120 can define a first refrigerated portion 101 and, more specifically, a first insulated enclosure or first refrigerated compartment 103 thereof. The base 110 can define a second refrigerated portion 102 and, more specifically, a second insulated enclosure or second refrigerated compartment 104 thereof. The rail 120 can be lowered and then compressed onto the base 110 and a seam defined therebetween can be sealed by a thermal break 219. The rail 120 can be secured by a series of fasteners 290 along the front and rear leading edges of the cabinet. As shown, a top surface of the rail 120 can be angled with respect to the horizontal. More specifically, the top surface of the rail 120 can be angled at or at least 5 degrees with respect to the horizontal.

[0062] The appliance 100 and, more specifically, the cabinet 105 and the base 110 can comprise an interior surface 211 and an exterior surface 212. The cabinet 105 can be defined by one or more of a bottom wall 213, a rear wall 214, side walls 215, a front frame 216, and an evaporator enclosure 217. The thermal break 219, which can be formed from a non-conductive or insulating material such as plastic, can interrupt or limit heat transfer between the exterior surface 212 and the interior surface 211 at any one or more connections therebetween. The cabinet 105, including in some aspects the closure device 130 and both the base 110 and the rail 120, can define the cabinet or base cavity 218. A portion of the base cavity 218 defined by the evaporator enclosure 217 can be separated from a remaining portion of the base cavity 218 defined by walls such as, for example and without limitation, the walls 213,214,215a,b by a return air duct 204.

[0063] The appliance 100 and, more specifically, the cabinet 105 and the rail 120 can comprise an interior surface 221 and the exterior surface 222 defined by the worktop portion 202 and the rail portion 203. More specifically, the rail 120 can comprise a rear wall 224, side walls, and a front wall 226. As with the thermal break 450, one or more other thermal breaks (not shown) can additionally or instead interrupt or limit heat transfer between the exterior surface 222 and the interior surface 221 at any one or more connections therebetween. More specifically, tape formed from an insulating material (e.g., double-sided tape comprising any insulating carrier, backing, or substrate) can be positioned between two adjoining panel formed from a conducting material to provide a thermal break. In some aspects, as shown, a panel 521 defining the interior surface 221 can comprise or be formed from a thermally conductive material such as, for example, metal. More specifically, the panel 521 can comprise or be formed from a corrosion-resistant metal such as stainless steel. In some aspects, a portion of the interior surface 221 and, more specifically, some or all of the interior surface 221 in contact with the thermal break 219 of the base 110 can be a thermal break, which can be formed from a non-conductive or insulating material such as plastic. In some aspects, the panel 521 can be planar or flat and can define both a ceiling of the base cavity 218 and the bottom of the worktop cavity 280. The rail 120, including in some aspects the closure device 140 (shown in both open and closed positions), can define a rail cavity 228 and the opening 208 defined at an outer or upper end thereof. The rail cavity 228 can be separated or divided into separate portions by a rail duct or duct 205, which can be secured to a surrounding portion of the rail 120 with fasteners 229. As shown, the rail duct 205 can be secured to one or more of the rear wall 224, the side walls 225 (shown in FIG. 4A), and the front wall 226 with the fasteners 229, which can be screws. The rear wall 224 and any portion thereof can be substantially vertical (closer to a vertical orientation than to a horizontal direction) or vertical (aligned with the vertical orientation).

[0064] The appliance 100 and, more specifically, the cabinet 105 can comprise various other panels or ducts. The cabinet 105 can comprise a main cabinet duct or roof duct 206, which can be secured to an underside of the rail 120 and can extend in a horizontal direction front to rear and left to right across a roof of the appliance 100 defined by the interior surfaces 211,221. The cabinet 105 can comprise a cabinet fan assembly 207, which can be coupled to the roof duct 206 and can be configured to deliver cold air to the base cavity 218 during normal operation. The appliance 100 can comprise a control interface 173, which can define an input to the controller 172 (shown also in FIG. 4B), which again can be configured to control overall operation of the appliance 100 and, more specifically, cooling of the rail 120. In some aspects, as shown, the control interface 173 can be positioned inside the appliance and, more specifically, on an interior surface such as the interior surface 211 of the second refrigerated portion 102. In some aspects, the control interface 173 can be positioned on an exterior surface such as the control interface 175 can be positioned on a surface of the front access panel 162.

[0065] The appliance 100 can comprise one or more storage components 410, each of which can receive stored product, e.g., food product in storage containers, thereupon. In some aspects, as shown, each of the storage components 410 can comprise or can be a shelf. In some aspects, each of the storage components 410 can comprise or can be a shelf slide or a set of shelf slides configured to receive shelves extending therebetween. In some aspects, each of the storage components 410 can comprise or can be a pan slide or a set of pan slides configured to receive storage pans (not shown) extending therebetween.

[0066] The rail duct 205 can define openings 480 in each of a rear wall 424 and a front wall 426. More specifically, the openings 480a,b can be configured to allow transmission or flow of air from behind the rail duct 205 and into a rail storage cavity or pan storage cavity or cavity 528 defined at least in part by the rail duct 205. In some aspects, as shown, each of the openings 480 can be a louver. In some aspects, each of the openings 480 can be a slot.

[0067] The appliance 100 and, more specifically, the raised rail 120 thereof can comprise or be configured to receive a plurality of food pans or pans 510. The plurality of pans 510 can comprise any desired combination of the pans 510, which typically are fractional sizes of a full-size “hotel” pan and configured to hold stored product such as, for example and without limitation, food ingredients for both refrigerated storage, display, and dispensing during a commercial food preparation process such as making a pizza or a sandwich. A full-size hotel pan can be and typically is sized to fit within a rectangular opening measuring 12 inches by 20 inches. Common or standard fractional sizes of a pan 510 include 1 / 9, ⅙, ¼, ⅓, ½ regular or short, and ½ long sizes. Fractional pans 510 used in combination can be configured to fit within the same pan opening as one full-size pan 510. For example, three ⅓-size pans 510 are typically configured to fit within the same pan opening as the full-size pan 510. In some aspects, each of the pans 510 can measure approximately 4 inches deep. In some aspects, each of the pans 510 can measure approximately 6 inches deep. In some aspects, a depth of each of the pans 510 can be smaller or greater. A variety of sizes can be combined to hold different amounts of food ingredients in different amounts, and positions to facilitate flexibility while using the appliance 100 and at the same time allow thorough cleaning of all that touches the food ingredients by removal and cleaning of the pans 510 and even the rail duct 205 as well as any exposed surfaces of surrounding portions of the appliance 100. The pan storage cavity 328 can be configured to receive one or more of the food pans 510.

[0068] In some aspects, for example and without limitation, the pan storage cavity 328 of a one-section appliance 100 defining a width W (shown in FIG. 1) of 46 inches can be configured to receive six ⅓-size pans; the pan storage cavity 328 of a two-section appliance 100 defining a width W of 60 inches can be configured to receive eight ⅓-size pans; the pan storage cavity 328 of a two-section appliance 100 defining a width W of 67 inches can be configured to receive nine ⅓-size pans; and the pan storage cavity 328 of a three-section appliance 100 defining a width W of 93 inches can be configured to receive twelve ⅓-size pans. One or more pan dividers (not shown) can be positioned between adjacent pans 510 of the plurality of pans 510.

[0069] The closure device 140 or any portion thereof of the rail 120 can be secured to the rail 120 and, more specifically, the second portion 124 and / or the third portion 126. The closure device 140 can slideably and / or hingeably open and close. More specifically, the closure device 140 and any portion thereof can open to one or more open positions, at which a position of the closure device 140 can be maintained indefinitely or until a user of the appliance 100 is ready to return the closure device 140 to a closed position also shown.

[0070] FIG. 6A is a schematic view of the refrigeration system 150 of the appliance 100 of FIG. 1. The refrigeration system 150 can comprise a condensing unit 610, an evaporating unit 650, and a refrigerant (not shown) received within each of the condensing unit 610 and the evaporating unit 650. The refrigeration system 150 can comprise tubing 605, which can join each of the components of the refrigeration system 150 configured to receive the refrigerant and can itself form at least a part of such components. The refrigerant can be configured to flow through each of the condensing unit 610 and the evaporating unit 650 and, ultimately, to remove heat from at least one of air and stored product received within the appliance 100.

[0071] The condensing unit 610 can comprise a compressor 620 and a condenser 630 in fluid communication with each other. The compressor 620 can be configured to transform a low-pressure gas entering the compressor 620 into a high-pressure hot gas exiting the compressor 620 by compression of the refrigerant, which can be a refrigerant such as R290, commonly known as propane. In some aspects, the refrigerant can be another gas able to facilitate heat transfer.

[0072] The condenser 630 can comprise tubing such as the tubing 605, which can be routed as desired, including in a serpentine fashion, to increase a surface area of the condenser 630 exposed to air flow and can by its shape and material facilitate heat transfer. In some aspects, the condenser 630 can further comprise fins, which can be coupled to the tubing and can further increase the surface area of the condenser 630 exposed to the air flow and can by its shape and material facilitate heat transfer.

[0073] The condensing unit 610 can further comprise a condenser fan 640, which can comprise a motor, a shaft coupled to the motor, and a fan blade coupled to the shaft. The condenser fan 640 can be configured to drive or blow air past or through the condenser 630 (and, less importantly, also the compressor 620) to remove heat therefrom (i.e., the condenser 630 can be configured to release heat into the air passing through the condenser 630). More specifically, As the condenser 630 is cooled by air driven by the condenser fan 640, the condenser 630 can transform the refrigerant therein from a high-pressure hot gas to a high-pressure liquid, thereby condensing the refrigerant.

[0074] The condensing unit 610 can comprise a filter-dryer 635, which can protect the refrigeration system 150 against contaminants and moisture. The condensing unit 610 can comprise a high-pressure safety switch 637, which can protect the refrigeration system 150 against high pressures by cutting off the compressor 620 and other components when a threshold high pressure is measured.

[0075] The evaporating unit 650 can be in fluid communication with the condensing unit 610. More specifically, the evaporating unit 650 can both receive the refrigerant from the condensing unit 610 and return the refrigerant to the condensing unit 610 in a continuous loop. The evaporating unit 650 can comprise a refrigerant metering device 660 and an evaporator 670 in fluid communication with each other.

[0076] The refrigerant metering device 660 can restrict or meter flow of the high-pressure liquid refrigerant from the condenser 630. The refrigerant metering device 660 can thereby transform the refrigerant from high-pressure lower temperature liquid to a low-pressure and low temperature liquid. In some aspects, the refrigerant metering device 660 can be a thermostatic expansion valve, sometimes referred to as a TXV or TEV. The TXV can be configured to dynamically adjust an orifice defined therein based on operation of the system and thereby adjust flow of the refrigerant through the TXV. More specifically, the TXV can be configured to accomplish such adjustment by placement of a bulb of the TXV on a suction line of the refrigeration system 150 (i.e., a section of the tubing 605 between the evaporator 670 and the compressor 620) and, in the process of sensing a temperature of the suction line with the bulb, causing a gas inside the bulb to effect opening and closing and, more generally, adjustment of the orifice. In some aspects, the refrigerant metering device 660 can be a capillary tube, which can define an internal diameter of, for example and without limitation, between 1.0 and 1.5 mm; and a length of, for example and without limitation, between 2000 and 2500 mm. While lacking certain features of the TXV, an inner diameter and length of the capillary tube can be set when building the refrigeration system 150 to sufficiently transform the properties of the refrigerant by the time the refrigerant enters the evaporator 670. In some aspects, the refrigeration system can comprise a suction line heat exchanger 665. More specifically, the refrigerant metering device 660, at least in the form of a capillary tube, can be brought within mating contact with the suction line over a length of each of the refrigerant metering device 660 and the suction line and thereby facilitate vaporization of any refrigerant in the suction line still in a liquid state after passage through the evaporator 670. The suction line heat exchanger 665 can protect the compressor 620 against “flooding” of the compressor with liquid refrigerant and in general can improve cooling performance of the refrigeration system 150.

[0077] More specifically, the evaporator 670 can comprise tubing such as the tubing 605, which can be routed as desired, including in a serpentine fashion, to increase a surface area of the evaporator 670 exposed to air flow and can by its shape and material facilitate heat transfer. In some aspects, the evaporator 670 can further comprise fins, which can be coupled to the tubing and can further increase the surface area of the evaporator 670 exposed to the air flow and can by its shape and material facilitate heat transfer.

[0078] The evaporating unit 650 can further comprise one or more evaporator fans 680, which can be configured to move air across the evaporator 670. Each of the evaporator fans 680 can comprise a motor, a shaft coupled to the motor, and a fan blade coupled to the shaft. Each of the evaporator fans 680 can be configured to drive or blow air past or through the evaporator 670 to absorb heat therefrom (i.e., the evaporator 670 can be configured to absorb heat from the air passing through the evaporator 670). As the evaporator 670 is cooled by air driven by the evaporator fans 680, the evaporator 670 can transform the refrigerant therein from a low-pressure low-temperature gas to a low-pressure higher-temperature gas, thereby evaporating the refrigerant. In some aspects, the evaporating unit 650 can be configured to supply cool air to an air plenum system of the appliance 100, which can be configured to cool the appliance 100. The air plenum system can comprise any of the cavities described elsewhere herein and configured to receive air flow.

[0079] The evaporating unit 650 can comprise a defrost thermistor or sensor 632 (shown in FIG. 6B), which can facilitate defrost of the evaporator 670 and thereby protect the refrigeration system 150 against the consequences of ice and / or frost on the evaporator 670, which can block air flow across the evaporator 670 and adversely impact heat transfer. The defrost thermistor 632 can come with the controller 172 and can be as specified from Danfoss A / S (e.g., Part No. 077F 08790). The evaporating unit 650 can comprise a defrost heater 634, which can protect the refrigeration system 150 against ice and / or frost on the evaporator 670 by applying heat to the evaporator 670 when a defrost cycle is initiated. More specifically, the defrost heater 634 can be an electric heater and can use conduction and / or radiation to apply heat to the evaporator 670. The evaporating unit 650 can comprise a defrost safety thermostat 636, which can protect the evaporator 670 and, more generally, the appliance 100 against overheating by prolonged operation of the defrost heater 634 that is not otherwise terminated. The evaporating unit 650 can comprise a drain collection device 638 (shown in FIG. 9A), which can further protect the refrigeration system 150 against ice and / or frost by directing moisture away from the evaporator 670 and from the evaporating unit 650 and can itself be heated as desired to protect against ice and / or frost on the drain collection device 638. In some aspects, the drain collection device 638 can be or can comprise a tray or pan.

[0080] FIG. 6B is a perspective view of the refrigeration system 150 of FIG. 6A. The condensing unit 610 can comprise the aforementioned components including the compressor 620 and the condenser 630. As shown, the condensing unit 610 can further comprise a condensate evaporating system 625. The condensate evaporating system 625 can comprise a collection device 627 configured to hold liquid condensate drawn from the evaporating unit 650. As shown, a drain tube 655 can capture the liquid condensate and direct same to the collection device 627 of the condensate evaporating system 625. In some aspects, a guide 657 can be secured to one of the condensing unit 610 and a surrounding structure of the refrigeration system 150 or, more generally, the appliance 100. The guide 657 can direct liquid condensate from the drain tube 655 to the collection device 627. In some aspects, the condensate evaporating system 625 can comprise a heating element 629. In some aspects, the heating element 629 can be a portion of the tubing 605 that is positioned between the compressor 620 and the condenser 630 and is filled with high-temperature gas during normal operation. In some aspects, the heating element 629 can be an electric heater or other heater. The heating element 629 can be received into the collection device 627.

[0081] In some aspects, the components of the condensing unit 610 can be assembled separately in a modular fashion, and the condensing unit 610 can be installed as an assembly. The condensing unit 610 for smaller versions of the appliance 100 such as, for example and without limitation, a one-section appliance 100 defining a width W (shown in FIG. 1) of 46 inches and a two-section appliance 100 defining a width W of 60 inches can be Model UMC3130U having a compressor capacity of approximately ⅓ horsepower and a heat rejection capacity of 800 BTU / hour or more; and the condensing unit 610 for larger versions of the appliance 100 such as, for example and without limitation, a two-section appliance 100 defining a width W of 67 inches and a three-section appliance 100 defining a width W of 93 inches can be Model EMC3134U having a compressor capacity of approximately ½ horsepower and a heat rejection capacity of 900 to 1,000 BTU / hour or more, both products being available from Embraco LLC and / or Embraco North America of Duluth, Georgia, U.S.A.

[0082] The evaporating unit 650 can comprise an evaporator shroud 685, which can be configured to position and support the evaporator fans 680 and can direct air through the evaporator 670. More specifically, the evaporator shroud 685 can comprise a first panel 682, to which the evaporator fans 680 can be secured and which can define matching openings (not shown) therein for passage of air through the evaporator fans 680. The evaporator shroud 685 can comprise a second panel 684, which can fit close to or even flush with a side of the evaporator to prevent short cycling of air around the evaporator and / or contain heat applied to the evaporator 670 during a defrost cycle. A quantity of the evaporator fans 680 can vary based on the air flow needed through the evaporator 670. For example and without limitation, the one-section appliance 100 defining a width W of 46 inches and the two-section appliance 100 defining a width W of 60 inches can comprise a pair of evaporator fans 680; and the two-section appliance 100 defining a width W of 67 inches and the three-section appliance 100 defining a width W of 93 inches can comprise three evaporator fans 680. Each of the evaporator fans 680 can be sized based on the size of the appliance 100 but in some aspects can deliver at least or approximately 106 CFM. Each of the evaporator fans 680 can be a Model UF12A-series alternating current (AC) product measuring 120 mm square and 38 mm thick and available from Mechatronics Fan Group of Preston, Washington, U.S.A. Various fasteners (not shown) can assemble the components of the condensing unit 610 and the evaporating unit 650 together and to each other.

[0083] In some aspects, as shown, the appliance 100 can comprise—and need only—one and only one instance of the refrigeration system 150. In some aspects, as also shown, the refrigeration system 150 can comprise—and need only—one and only one compressor 620 for cooling (e.g., each of the first refrigerated portion, the second refrigerated portion, and the worktop cavity). In such aspects, it can be beneficial in terms of cost, energy efficiency, serviceability, and other reasons for the appliance 100 to require only a single refrigeration system 150 and / or a single compressor 620.

[0084] FIG. 7 is a schematic view of an airflow circuit 700 of the appliance 100 of FIG. 1. As shown, air can be pulled from the base cavity 218 of the cabinet or base 110. The air can then be pulled through the evaporator 670 and through the evaporator fans 680 by the evaporator fans 680. The air can then be pulled through the rail cavity 228 and, more specifically, the pan storage cavity 428 defined by the rail 120. The air can then be also pulled from the rail 120 through the one or more cabinet fan assemblies 207 by the cabinet fan assemblies 207 into the base cavity 218 or can bypass the base cavity 218 and return to the evaporator 670. In some aspects, as shown, the evaporator fans 680 can be positioned above or on an outlet side of the evaporator 670 and can pull air through the evaporator 670. In some aspects, the evaporator fans 680 can be positioned below or on an inlet side of the evaporator 670 and can push air through the evaporator 670.

[0085] FIG. 8 is a detail front perspective view of a left side of the cabinet 105 of the appliance 100 of FIG. 1 showing the control interface 173 of the primary controller 172 and the control interface 175 of the secondary controller 174. The control interface 173 of the primary controller 172 can be configured to control an air temperature of the rail portion 203 (shown in FIG. 5) of the rail 120; and the control interface 175 of the secondary controller 174 can be configured to control an air temperature of an interior cavity such as the base cavity 218 of the base 110. In some aspects, as shown, the control interface 173 can comprise a dial control. In some aspects, the primary controller 172 can be a Model ERC113C-series product from Danfoss A / S of Nordborg, Denmark. In some aspects, the primary controller 172 can control operation of the compressor 620, the defrost system, the evaporator fans 680, and can switch between “day” mode and “night” mode as discussed in U.S. application Ser. No. 17 / 889,249, filed on Aug. 16, 2022. Additionally, however, each of the one or more closure devices 140 and, more specifically, each of the one or more rail lids, can trigger a transition between day mode and night mode and thereby automatically adjust the temperature setpoint of the rail 120 by the unit sensing a position of the closure device 140 and making the adjustment. More specifically, in the case of multiple closure devices 140, a position of each closure device 140 can be separately monitored by a separate sensor 450, which can be exemplarily positioned relative to each closure device 140 as disclosed in U.S. application Ser. No. 17 / 889,249 or otherwise as desired. In some aspects, for example and without limitation, the sensor 450 for each closure device 140 can be positioned in a hidden area of the third portion 126 of the rail 120 (for example and without limitation, between where individual covers 270 are positioned in the storage area 128, and housed within enclosures as desired). More specifically, the sensor 450 can be a door switch with a rotating contact element configured to selectively engage and disengage with a surface of the closure device 140. During use, returning any one of the closure devices 140 to its storage location and thereby exposing a portion of the rail 120 can result in an adjustment to day mode—even if the other closure devices 140 are still covering the remaining portion(s) of the rail 120—and with the adjustment can increase cooling to the rail. In some aspects, the secondary controller 174 can be a Model E31B-series product from Ascon Technologic S.r.L. of Vigevano, Italy. In some aspects, the secondary controller 174 can control operation of the cabinet fans 1010.

[0086] The front access panel 162 can comprise an air inlet opening 868, through which the condenser fan 640 (shown in FIG. 6B) can draw air across the condenser 630 (shown in FIG. 6B). In some aspects, the air inlet opening 868 can be defined and / or covered by a grill 864. More specifically, the grill 864 can comprise a filter 866, which can be washable and / or replaceable with or without tools, depending on user requirements.

[0087] FIG. 9A is a sectional view of the appliance of FIG. 1 taken along line 9A-9A of FIG. 5, and FIG. 9B is a detail sectional view of the appliance 100 taken along line 9B-9B of FIG. 9A in accordance with another aspect of the current disclosure and showing only geometry in the cut plane. As will be described in further detail below, airflow alone through the appliance 100 and, more specifically, the first refrigerated portion 101 can distribute cold air throughout the pan storage cavity 428 and around each pan 510 (shown in FIG. 5) and can properly maintain air and product temperatures throughout the first refrigerated portion 101.

[0088] The appliance 100 need not use “cold wall” construction to cool the rail portion 203 of the rail 120 properly as in appliances that are typically available. As such, the rail 120 and associated structures can define a non-cold-wall construction, which means that no walls of the first refrigerated compartment or first insulated enclosure 103 nor pan dividers nor ducts between adjacent pans 510 that are configured to be received within the pan storage cavity 428 contain any refrigerated tubing. In an appliance defining “cold wall” construction, either refrigerant or glycol is typically circulated through tubes, which are typically formed from copper and embedded inside the walls of the rail. Rails of such units typically have separate evaporators and sometimes have separate and distinct refrigeration circuits. Such “cold wall” rails must typically be defrosted manually, which under some circumstances and without care cause damage to the rail caused, for example, by forceful removal of built-up ice that is not an issue with the structures disclosed herein. Again, in contrast, the appliance 100 need comprise only a single refrigeration system 150 and need comprise only a single evaporator 670 together with the one or more cabinet fan assemblies 207, which can be configured to regulate cooling of the cabinet through an air plenum on an as-needed basis. Such a construction can be significantly more expensive to build and less serviceable than the structures and methods disclosed herein.

[0089] Among designs by others using an air-cooled method, air is typically forced from the rail into the cabinet through an open duct regardless of cooling need (i.e., with no dynamic control), which can lead to food product freezing in a cabinet that ordinarily should be maintained above freezing temperatures. In addition, the rail ducts are typically fixed, i.e., not removable, which is an obstacle to regular and / or thorough cleaning. Using one or more of the improvements disclosed herein, however, the rail and cabinet temperatures can be adjusted and controlled automatically and independently.

[0090] The appliance 100 and, more specifically, the first refrigerated portion 101 (which can be defined at least in part by the rail 120) and the second refrigerated portion 102 (which can be defined at least in part by the base 110) can define an intake air cavity 910 therebetween. More specifically, the intake air cavity 910 can be defined between a top surface 901 of the roof duct 206 and the outward-facing surface 422 defined by the bottom wall 423 of the rail duct 205. The roof duct 206 can further define a bottom surface 902. The intake air cavity 910 can be further defined between the interior surface 221 (shown in FIG. 9B) of the rear wall 224 (shown also in FIG. 9B) of the first refrigerated compartment 103 and the outward-facing surface 422 defined by the rear wall 424 of the rail duct 205. As shown, the intake air cavity 910 can be in fluid communication with an evaporator cavity 980, which can be defined by the base 110 of the cabinet 105 and can house the evaporating unit 650 (shown in FIG. 6A) of the refrigeration system 150 (shown in FIG. 6A) and can be configured to receive air supplied by the evaporating unit 650. An inlet duct 920 can separate a supply side 980a of the evaporator cavity 980 from a return side 980b of the evaporator cavity 980. The return air duct 204 can separate the evaporator cavity 980 from the base cavity 218.

[0091] As shown in FIG. 9B, a rail inlet divider or first divider 930 of the rail 120 and, more generally, the appliance 100 can separate the intake air cavity 910 from a communication air cavity 938 configured to receive air that has circulated already through the first refrigerated compartment 103, which can be defined by the rail 120. More specifically, the first divider 930 can separate the intake air cavity 910 from the communication air cavity 938 along an entire length of the roof duct 206. The roof duct 206 itself can comprise a bottom panel 903, a rear panel 904, a front panel 906, side panels, and a mounting flange 927.

[0092] With the first divider 930 positioned as shown and sealing a gap between the rail duct 205 and the roof duct 206, air circulating from the evaporator cavity 980 into the intake air cavity 910 can be encouraged, as a general matter, to continue in the longitudinal direction 403 of the rail duct 205 (shown in FIG. 9A) down a length of the first refrigerated compartment 103. Along the way and upon reaching the far end of the intake air cavity 910 distal from the evaporator cavity 980, the intake air cavity 910 can naturally direct all air to the rear and up between the rear wall 424 of the rail duct 205 and the rear wall 224 of the rail 120. The rail duct 205 can then be configured to receive such cool air through the openings 480a. Thus, below the rail duct 205, the intake air cavity 910 can be an air plenum and can be configured to pressurize the air from the evaporator cavity 980 and evenly distribute the air throughout the first refrigerated compartment 103, which again can be defined by the rail 120.

[0093] The air can flow through the openings 480a and can flow through other openings and then into the rail cavity 228. Due to geometric considerations, in some aspects the air can flow differently in a left front corner of the rail. The air can circulate through the rail cavity 228 and around the plurality of pans 510 (shown in FIG. 5) positioned therein. The air can then flow through the openings 480b and into the communication air cavity 938 in a direction towards the base cavity 218. Again, the openings 480a, b can be sized and positioned to evenly distribute air in the pan storage cavity 428 such that each pan 510 receives a similar amount of air flow and can be maintained at temperatures that are within a predetermined range.

[0094] The properties (e.g., size, locations, and quantities) of the openings 480, including supplemental openings 486a, can be defined in the rail duct 205 as shown to facilitate maintenance of proper temperatures inside the first refrigerated compartment 103 of the first refrigerated portion 101, which can be defined by the rail 120. These properties can be optimized based on simulation of various structures using manufacturing considerations (e.g., the availability of standard tooling), simulation (e.g., computational fluid mechanics or CFM), and actual testing of the appliance. Various other exemplary dimensions and characteristics of the appliance 100 can be based at least in part on spatial constraints (e.g., dimensions of both the base 110 and the rail 120 being based at least in part on the size of fractional hotel pans 510 shown in FIG. 5A, a height of the roof duct 206 being based on at least in part on a thickness or height of a cabinet fan 1010, and various other dimensions based on customer requirements and supplier part specifications).

[0095] The combination of openings 480 can be optimized for each size model and as disclosed herein are based on conditions set by NSF / ANSI (National Sanitation Foundation / American National Standards Institute) Standard 7 for Commercial Refrigerators and Freezers, which specifies in part four-inch-deep half-size pans containing a simulated food material (a special methylcellulose mixture) and an ambient temperature of 86° F. (30° C.). Under the NSF / ANSI Standard 7 test conditions, temperatures measured at certain points inside the pans 510 (shown in FIG. 5A) must remain within a range of 0.6° C. to 5.0° C. over a full four-hour testing period, and lagged temperatures (i.e., temperatures measured by thermocouples placed inside special weighted lags) placed in precise locations inside the base cavity 218 must remain within a range of 0° C. to 4.4° C. over the same testing period.

[0096] In different operating conditions (e.g., deeper pans, a different ambient temperature, air circulation inside room, and / or properties of actual food product stored in the appliance 100 and, more specifically, the rail 120) and even under otherwise compliant NSF / ANSI Standard 7 test conditions, a different combination of openings and other settings can be sufficient to main temperatures at levels satisfactory to a user of the appliance 100 in the different operating conditions. Moreover, other dimensions of the appliance 100 including the size and position of the rail duct 205 and, more generally, the configuration of the rail 120 and various ducting components are similarly optimized based on conditions generally set by NSF / ANSI Standard 7 but can generally also be modified based on different operating conditions. To the degree that a single range of conditions is neither required nor present in actual use of the appliance 100, and to the degree that NSF / ANSI Standard 7 conditions are more exacting than some users require, various combinations are conceivable where user requirements allow for different conditions; and the combinations shown are therefore intended to be exemplary. In some aspects, the modifications that would be appropriate for a change in conditions will be understood by one who is skilled in the art. In some aspects, the appliance 100 can comply with the safety requirements—particular electrical safety requirements—of UL 471 for Commercial Refrigerators and Freezers.

[0097] Across at least a portion of the roof duct 206, a return divider or second divider 940 of the rail 120 and, more generally, the appliance 100 can separate the communication air cavity 938 from a return air cavity 948 and can thereby discourage or prevent “short cycling” of air that has circulated into and out of the pan storage cavity 428 through the rail duct 205. Instead, such air can be directed by the second divider 940 towards the one or more cabinet fan assemblies 207. Depending on the cooling needs of the base 110 and the base cavity 218, the air can then circulate through the base cavity 218 and can then return to the evaporator cavity 980, or the air can bypass the base cavity 218 and return directly to the evaporator cavity 980. A conduit or wire chase 950 can house at least a portion of wiring extending from the cabinet fan assemblies 207 to the controls system 170 (shown in FIG. 3) and through the base cavity 218. More specifically, the conduit 950 can define a closed shape after assembly and can define one or more panels, which can be angled with respect to each other.

[0098] The second divider 940 can extend partly across the roof duct 206 in the longitudinal direction 403 and, more generally, the cabinet 105, to reduce or prevent short cycling air that has already passed through the pan storage cavity 328 (shown in FIG. 9B) and is on its way toward the base cavity 218. In some aspects, more specifically, the second divider 940 can extend up to the first cabinet fan assembly 207 to ensure that air that has already passed through the pan storage cavity 428 closer to the evaporator cavity 980 is available to the cabinet fan assembly 207 closest to the evaporator cavity 980. In some aspects, one or more supplemental dividers 940a, b can be shaped similarly as the second divider 940 and can be secure a portion of the roof duct 206 to at least one of the interior surfaces 211,221. Between the one or more supplemental dividers 940a, b and between the one or more supplemental dividers 940a, b and the second divider 940, air can freely flow from the communication air cavity 938 to the return air cavity 948. Various fasteners (not shown) can assemble the dividers 930,940 to surrounding structures such as the roof duct 206. In some aspects, the dividers 930,940 can be welded (e.g., with spot welds) to the roof duct 206. In some aspects, a strip of insulation or a gasket material can be positioned on top of either of the dividers 930,940 and the mating structure to reduce or prevent air leakage through the connection.

[0099] FIG. 10 is a bottom perspective view of the cabinet fan assembly 207 of the appliance of FIG. 1. The cabinet fan assembly 207 can comprise the cabinet fan 1010. The cabinet fan 1010 can feed cold rail air through a cabinet fan enclosure 1020, which can evenly distribute air into the base cavity 218. More specifically, the cabinet fan 1010 can feed cold rail air through one or more openings 1028 defined in the cabinet fan enclosure 1020. The one or more openings 1028 can be distributed across one or more walls of the cabinet fan enclosure 1020. In some aspects, the cabinet fan enclosure 1020 can comprise a bottom wall 1023, a rear wall 1024 (shown in FIG. 11), side walls 1025, a front wall 1026, and one or more mounting flanges (not shown). As shown, a single opening 1028 can be defined in the bottom wall 1023. The cabinet fan assembly 207 can comprise a fan grill 1060, which can permit substantial air flow through the opening 1028 but prevent access by a user and can prevent physical objects from interfering with the rotation of the cabinet fan 1010. The cabinet fan assembly 207 can comprise the conduit 950, which can permit passage of electrical wires to the cabinet fan 1010 from a power source elsewhere on the appliance 100 but prevent access by the user and / or the other physical objects.

[0100] The cabinet fan 1010 can be an axial fan in which an air flow direction is parallel to an axis of rotation. The cabinet fan 1010 can define an air inlet or inlet (not shown) above the cabinet fan 1010, which can be configured to receive intake air in a direction parallel to an axis 1011 of the cabinet fan 1010, i.e., in an axial direction with respect to the axis 1011. The cabinet fan 1010 can define an air outlet or outlet 1014, which can be configured to expel exhaust air 1015 in a direction that is also parallel to the axis 1011, i.e., in a radial direction with respect to the axis 1011. In some aspects, the cabinet fan 1010 can be a blower fan in which the direction of air flow changes between the inlet and the outlet 1014.

[0101] The inlet of the cabinet fan 1010 can be aligned with the cabinet opening 1080 in the roof duct 206. In some aspects, as shown, the cabinet fan 1010 can be mounted to the cabinet fan enclosure 1020 and the cabinet fan enclosure 1020 can be secured to the roof duct 206. More specifically, one or more fasteners 1090 can extend through holes 1423 defined in the cabinet fan enclosure and can engage the roof duct 206 (e.g., with threaded inserts installed therein). In some aspects, the cabinet fan enclosure 1020 can further define an opening (not shown) for receipt of a lead wire connecting the cabinet fan 1010 to a cabinet fan relay or switch.

[0102] FIG. 11 is a detail sectional view of the appliance 100 of FIG. 1 taken from detail 11 of FIG. 5. As shown, the air that has already passed through the pan storage cavity 428 can also be freely received, as cooling needs dictate, into a cabinet opening 1080 defined in the roof duct 206 and through the cabinet fan 1010 of the cabinet fan assembly 207. The cabinet fan 1010 of each cabinet fan assembly 207 can be controlled by a separate thermostat such as a cabinet thermistor 1540 (shown in FIG. 10) in communication with the secondary controller 174 (shown in FIG. 1) or by a second temperature sensor (e.g., cabinet thermistor 1540) extending from the primary controller 172 (shown in FIG. 3).

[0103] As shown, the catch pan 260 can be received inside the worktop cavity 280 such that a surface of the catch pan 260 (e.g., a bottommost surface) is in contact with the interior surface 221 and, more specifically, the panel 521 of the worktop portion 202 of the rail 120. As such, a gap 1170 between an upper surface of the panel 521 and the nearest surface of the catch pan 260 can be zero, which can result in conduction of heat from the catch pan 260 into the panel 521, which can be cooled as described elsewhere herein. In some aspects, as shown, the portion of the catch pan 260 contacting the panel 521 can be planar, which can maximize the surface area in contact with the panel 521, which can also be planar.

[0104] A quantity of cabinet fans 1010 can vary based on the air flow needed through the cabinet fan assemblies 207. For example and without limitation, the one-section appliance 100 defining a width W (shown in FIG. 1) of 46 inches and the two-section appliance 100 defining a width W of 60 inches can comprise a single cabinet fan assembly 207 comprising a single cabinet fan 1010; and the two-section appliance 100 defining a width W of 67 inches and the three-section appliance 100 defining a width W of 93 inches can comprise a pair of cabinet fan assemblies 207, each comprising a cabinet fan 1010. Each of the cabinet fans 1010 can be sized based on the characteristics of the particular appliance 100 and the conditions of use but in some aspects as shown and tested can deliver at least or approximately 21 CFM. In some aspects, each of the cabinet fans 1010 can be a Model UF90DPB-series alternating current (AC) product measuring 120 mm square and 37 mm thick and available from Mechatronics Fan Group of Preston, Washington, U.S.A. In some aspects, as shown, one or more of the cabinet fans 1010 can be an axial fan of equivalent or greater capacity (e.g., CFM). Various fasteners (not shown) can assemble the components of the cabinet fan assemblies 207 together and to surrounding structures. On the unit shown, the cabinet fans 1010 can be positioned as shown. On a larger three-section unit measuring 93 inches wide, the cabinet fan 1010 can be positioned behind the divider 112 (shown in FIG. 2). In some aspects, the cabinet fan 1010 can be positioned symmetrically inside the base cavity 218. As shown, the cabinet fan 1010 can be positioned in front of the front wall 226 of the rail 120. As also shown, the cabinet fan 1010 can drive air into the base cavity 218 in a direction away from the main openings 118 and away from the closure devices 130 to reduce the risk of increased air leakage through the main openings 118.

[0105] Closer to a front of the appliance 100, a divider or shroud 1030 can separate the supply side 980a from the return side 980b of the evaporator cavity 980. In some aspects, a strip of insulation or a gasket material can be positioned on top of or around some or all of a perimeter of the shroud 1030 and between the shroud 1030 and the mating structure (e.g., one or more surfaces of the evaporator cavity 980 and / or the roof duct 206) to reduce or prevent air leakage through the connection.

[0106] The thermal break 219 can comprise one or more of several sealing structures including a bellows-style compressible portion, a rigid polymer extrusion and a compressible gasket. In some aspects, the various portions of the thermal break 219 can be formed integrally as a single component. In some aspects, the various portions of the thermal break 219 can be formed as separate components.

[0107] FIG. 12 is a top perspective partially cutaway view of a left end of a cabinet 105 of the appliance 100 of FIG. 1, and FIG. 13 is a top cutaway view of the return air opening of the left end of the cabinet 105 of FIG. 12, each with at least a portion of the worktop portion 202 of the rail 120 removed for clarity The roof duct 206 can define a return air opening 1380, which can allow passage of air from the return air cavity 948 to the evaporator cavity 980 and specifically the return side 980b thereof. In some aspects, the return air opening 1380 can define any polygonal or other closed shape. In some aspects, the return air opening 1380 can define a plurality of openings (e.g., slots), but fewer openings can facilitate less restriction to air flow.

[0108] A rail thermistor or rail sensor or sensor 1320, which can be a first control input or first sensor, can be mounted to the shroud 1030 in a mounting location 1325. The rail thermistor 1320 can come with the controller 172 and can be as specified from Danfoss A / S (e.g., Part No. 077 08767). In some aspects, the rail thermistor 1320 can be mounted to any other interior structure of the return air cavity 948 or the return side 980b of the evaporator cavity 980. In some aspects, the rail thermistor 1320 can be mounted with a wire tie (not shown), which can be configured to firmly hold the rail thermistor 1320 and prevent it from touching any surrounding metal or other interior surface. More specifically, a barbed attachment of a mounting portion of the wire tie can be received into a hole in the mounting surface, and a securing portion of the wire tie can receive and adjustably tighten around the rail thermistor 1320. For example and without limitation, the wire tie can be P / N PLT2D-M available from Vallen Distribution. The rail thermistor 1320 can be in electrical communication with the controller 172 (shown in FIG. 3).

[0109] The cabinet thermistor or cabinet sensor or control input or sensor 1540 (shown in FIG. 10), which can be a second control input or second sensor, can be mounted to an underside of the roof duct 206 in a mounting location 1345 (shown in FIG. 10). The cabinet thermistor 1540 can come with the secondary controller 174 (shown in FIG. 1) and can be as specified from Ascon Technologic S.r.L. (e.g., Part No. NTC-TPEGY-A1). In some aspects, the cabinet thermistor 1540 can be mounted to any other interior structure of the base cavity 218 that will not interfere with operation of the appliance 100. In some aspects, the cabinet thermistor 1540 can be mounted with a wire tie configured to firmly hold the cabinet thermistor 1540 and prevent it from touching any surrounding metal or other interior surface. More specifically, a barbed attachment of a mounting portion of the wire tie can be received into a hole in the mounting surface, and a securing portion of the wire tie can receive and adjustably tighten around the cabinet thermistor 1540. For example and without limitation, the wire tie can be a wire tie as noted above. The cabinet thermistor 1540 can be in electrical communication with the secondary controller 174 or, in the case of a single controller controlling both cabinet and rail air temperatures, the controller 172.

[0110] FIG. 14 is an exploded top right perspective view of the appliance 100 of FIG. 1 showing the catch pan 260 of FIG. 4D and associated parts, FIG. 15 is a sectional view of the appliance 100 of FIG. 1 taken along line 15-15 of FIG. 14, and FIG. 16 is a detail sectional view of the appliance 100 of FIG. 1 taken from detail 16 of FIG. 15. As shown, a portion of the worktop cavity 280 can be configured to receive the catch pan 260, the cover 270, and / or the worktop support 250. As shown, each of the catch pan 260, the cover 270, and / or the worktop support 250 can be removable through a top of the worktop opening 280. Each of the catch pan 260 and the cover 270 can be sized and otherwise configured to be received within the worktop cavity 280.

[0111] As shown in FIG. 16, the worktop support 250 can be sized and otherwise configured to be received within a larger workspace available above the worktop cavity 280 and in some aspects extending even past a front nose of the appliance 100. More specifically, as described above, the support bracket 420 can support a portion of the worktop support 250 in the vertical (up-down) and horizontal (front-rear) directions of the appliance 100. As shown, the support bracket 420 can have or define a “Z” shape in cross-section, which can comprise a first vertical portion 422, a horizontal portion 424, and a second vertical portion 426. For example and without limitation, the first vertical portion 422 can be securable to the rail 120, the horizontal portion 424 can support a lower end or side of the worktop support 250, and the second vertical portion 426 can restrain a front end or side of the worktop support 250. As shown, a catch guard 1650 can be secured to the worktop support 250 and prevent spillage of food ingredients past a front edge of the appliance 100. More specifically, the catch guard 1650 can have or define a “Z” shape in cross-section. More specifically, the catch guard can comprise a first vertical portion 1652, a horizontal portion 1654, and a second vertical portion 1656. For example and without limitation, the first vertical portion 1652 can be securable to the worktop support 250 by being restrained against a vertical surface of the worktop support 250, the horizontal portion 1654 can be supported by an upper end or side of the worktop support 250, and the second vertical portion 1656 can restrain or limit movement or “catch” ingredients that might otherwise fall off the front edge of the rail 120 and, more generally, the appliance 100.

[0112] FIG. 17 is a top perspective view of the catch pan 260 of FIG. 4D, and FIG. 18 is a bottom perspective view of the catch pan 260 of FIG. 4D. The catch pan 260 can comprise a main panel 1710. The main panel 1710 can define four ends. The catch pan 260 can comprise one or more first flanges or flanges 1720, each of or any of which can extend from the main panel 1710. More specifically, each of or any of the one or more first flanges 1720 can be angled with respect to the main panel 1710 and can thereby form a wall, which can define a height of the catch pan 260. The catch pan can comprise one or more second flanges or flanges 1730, each of or any of which can extend from one of the corresponding first flanges 1720. More specifically, each of or any of the one or more second flanges 1730 can be angled with respect to one of the corresponding first flanges 1720. The catch pan 260 can comprise a handle 1750, which can be releasably secured to a remaining portion of the catch pan 260 and, more specifically, the main panel 1710 with one or more fasteners 1759. Each of or any of corners at which the first flanges 1720 and / or the second flanges 1730 intersect or approximately join can comprise a weldment or other fastening structure 1790. By attaching a single handle 1750 to the catch pan 260, a force to remove the catch pan 260 can be centered and removal can be facilitated.

[0113] FIG. 19 is a top perspective view of the cover 270 of FIG. 4E, and FIG. 20 is a bottom perspective view of the cover 270 of FIG. 4E. The catch pan 260 can comprise a main panel 1910. The main panel 1910 can define four ends. The catch pan 260 can comprise one or more first flanges or flanges 1920, each of or any of which can extend from the main panel 1910. More specifically, each of or any of the one or more first flanges 1920 can be angled with respect to the main panel 1910. The catch pan can comprise one or more second flanges or flanges 1930, each of or any of which can extend from one of the corresponding first flanges 1920. More specifically, each of or any of the one or more second flanges 1930 can be angled with respect to one of the corresponding first flanges 1920. In some aspects, as shown, each of the second flanges 1930 can be or comprise a hem, which can ease installation of the cover 270 and / or further reinforce the cover 270. The catch pan 260 can comprise a handle 1950, which can be releasably secured to a remaining portion of the catch pan 260 and, more specifically, the main panel 1910 with one or more fasteners 1959. Each of or any of corners at which the first flanges 1920 and / or the second flanges 1930 intersect or approximately join can comprise a weldment or other fastening structure 1990. By attaching a pair of handles 1950 to the cover 270, one of the handles 1950 can be made accessible to a user while the cover 270 is stored inside an upper portion of the rail 120 (e.g., the third portion 126). The cover 270, which can be made flush with the surrounding surface of the thermal break 450 and / or the worktop portion 202, can facilitate overnight operation of the appliance 100 with minimal heat transfer into the appliance 100 through the worktop cavity 280.

[0114] FIG. 21 is a top plan view of the appliance 100 of FIG. 1. In some aspects, as shown, an overall width of the worktop opening 280 can be divided into equal parts as an effective catch pan width 2180. In some aspects, the catch pan 260 and the dimensions of the worktop cavity 280 can be as desired by a user. A width 2170 of a side of the worktop portion 202 surrounding the worktop cavity 280 (and similarly, a width of a front or rear of the worktop portion 202) can be sized to facilitate the flow of foam insulation and to facilitate a seal between the rail 120 and the base 110.

[0115] FIG. 22 is a detail top perspective view of the worktop cavity 280 of the appliance 100 of FIG. 1 showing the thermal breaker or thermal break 450 defining a perimeter of the worktop cavity 280, and FIG. 23 is a detail sectional view of the worktop portion 202 of the appliance of FIG. 1 taken from line 23 -23 of FIG. 22 and showing a cross-section of the thermal break 450. The thermal break 450 can extend from the panel 521 to the upper or outer panel of the worktop portion 202 of the rail 120. The thermal break 450 can define a shoulder 2215, which can support the catch pan 260 and, more specifically, the second flanges 1730 thereof. A width of the shoulder 2215 can facilitate sealing of a gap between the catch pan 260 and the thermal break 450 by extending a distance along which air must travel to escape from an area between the catch pan 260 and the thermal break 450. Separate pieces of the thermal break can be joined at a miter joint, with or without welding. In some aspects, a frame formed by portions of the thermal break 450 can be preassembled and dropped into a surrounding structure of the rail 120. As with other cavities formed by the various inner and outer panels of the rail 120 and the base 110, foam can be injected inside as insulation to increase resistance against heat transfer into the appliance 100 from an ambient environment.

[0116] FIG. 24 is a detail top perspective view of the appliance 100 of FIG. 1 showing the catch pan 260 of FIG. 4D overlapping with an adjacent catch pan 260 by an overlap distance 2470. In some aspects, the catch pans 260 and the dimensions of the worktop cavity 280 can be sized to produce such overlap, i.e., an average overlap distance greater than zero, in order to reduce gaps from which cold can escape from—or heat can be absorbed by—the worktop opening 280. The overlap distance 2470 can be measured between edges of the second flanges 1730.

[0117] A method of using the appliance 100 can comprise distributing air through an air plenum system of the appliance 100 and, more specifically, throughout the pan storage cavity 428 and around the pans 510 to maintain proper temperatures of food product stored therein. More specifically, the method can comprise complying with NSF / ANSI Standard 7 performance requirements in an ambient temperature of 86° F. (30° C.). The method can comprise complying with NSF / ANSI Standard 7 pan temperature requirements in an ambient temperature of 100° F. (37.8° C.). The method need not comprise distributing refrigerant as is typical in the aforementioned “cold-wall” design. The method can comprise properly maintaining air and product temperatures throughout the first refrigerated portion 101. The method can comprise cooling a first refrigerated portion 101 and a second refrigerated portion 102 with only a single refrigeration system 150 comprising only a single evaporator 670. The method can comprise regulating a temperature of the base cavity 218 with one or more cabinet fans 1010 only as needed based on input from a sensor such as the cabinet thermistor 1540.

[0118] A method of distributing air can comprise moving refrigerated air from an evaporator cavity 980 to the intake air cavity 910. The method can comprise moving air through the intake air cavity 910 in the longitudinal direction 403 along a length of the rail 120. The method can comprise directing air inside the intake air cavity 910 towards the rear wall 224 of the rail 120 and up between the rear wall 424 of the rail duct 205 and the rear wall 224 of the rail 120. The method can comprise moving air through the openings 480a such as, for example and without limitation, one or more of the air transmission openings 482a, the handle openings 484a, and the supplemental openings 486a. The method can comprise moving air, in one or more corners of the rail 120, through the openings 480b such as, for example and without limitation, other supplemental openings. The method can comprise pressurizing air from the evaporator cavity 980 and thereby distributing air throughout the first refrigerated compartment 103. The method can comprise circulating air through the pan storage cavity 428 and around the plurality of pans 510 positioned therein. In some aspects, as shown, the method can comprise moving air from the rear of the rail 120 to the front of the rail 120 (i.e., front-to-back). In some aspects, by reconfiguring the rail duct 205 and the roof duct 206 the method can comprise moving air from the front of the rail 120 to the rear of the rail 120. The method can comprise moving air through the openings 480b and into the communication air cavity 938 in a direction towards the base cavity 218.

[0119] The method can comprise moving air from the pan storage cavity 428 to the communication air cavity 938. As such, the method can comprise moving air around an obstacle (e.g., the second divider 940) separating the communication air cavity 938 and the return air cavity 948 for a sufficient distance to discourage or prevent short cycling of air back to the evaporator cavity 980 before reaching the base cavity 218. The method can comprise moving air towards the one or more cabinet fan assemblies 207 in a direction parallel to the obstacle.

[0120] When the base cavity 218 does not require further cooling, the method can comprise bypassing the base cavity 218, i.e., returning some or all of the air directly to the evaporator cavity 980 without going through the base cavity 218. When the base cavity 218 does require further cooling, the method can comprise circulating the air through the base cavity 218 and then can comprise returning the air to the evaporator cavity 980.

[0121] More specifically, the method can comprise moving air through the cabinet opening 1080 defined in the roof duct 206 and through the cabinet fan 1010 of the cabinet fan assembly 207. The method can comprise controlling the cabinet fan 1010 by a separate thermostat, e.g., the cabinet thermistor 1540, of the secondary controller 174 or by a second temperature sensor extending from the primary controller 172. The method can comprise moving air through the cabinet fan enclosure 1020, which can evenly distribute air into the base cavity 218. The method can comprise moving air through the openings 1028 defined in the cabinet fan enclosure 1020. The method can comprise moving air into the base cavity 218 in a direction away from the main openings 118 and away from the closure devices 130 to reduce the risk of increased air leakage through the main openings 118. The method can comprise moving air from the base cavity 218 to the evaporator cavity 980. The method can comprise moving air from the base cavity 218 to the return side 980b of the evaporator cavity 980 through the return air opening 1380, which can be defined in a lower surface of the roof duct 206.

[0122] The method can comprise regulating a temperature of air circulating through the rail cavity 228 between the intake air cavity 910 and the return air cavity 948 with the rail thermistor 1320, which again can be mounted inside the return side 980b of the evaporator cavity 980. The method can comprise regulating a temperature of air circulating through the base cavity 218 with the cabinet thermistor 1540, which again can be mounted inside the base cavity 218.

[0123] The method can comprise receiving the intake air 1413 into an inlet 1412 of cabinet fan 1010 along the axis 1411 of the cabinet fan 1010 and expel exhaust air 1415 in a direction perpendicular to the axis 1411. Thus the method can comprise changing the direction of air flow between the inlet 1412 and the outlet 1414. In some aspects, the method can comprise drawing air from inside the roof duct 206 and directing such air into and through an air distribution duct 1520 that is separate from the cabinet fan enclosure 1020.

[0124] The method can comprise cooling the ceiling of the base 110, which can comprise simultaneously cooling an interior surface 221 of the rail and, more specifically, a panel 521 defining the interior surface 221. The method can comprise inserting the catch pan 260 into the worktop cavity 280, which can comprise contacting the panel 521 with a portion of the catch pan 260 and, more specifically, a bottommost surface or main panel 1710 of the catch pan 260. More specifically, the method can comprise cooling the catch pan 260 by conduction and thereby regulating a temperature of food ingredients caught therein during use of the appliance 100. The method can comprise not blowing air over the catch pans, which can dry the food ingredients.

[0125] In some aspects, various components of the appliance 100 can be formed from or comprise a metal such as, for example and without limitation, steel. More specifically, components exposed to food and / or liquids including cleaning fluids including the user-facing surfaces of the appliance can be formed from or comprise stainless steel. Materials configured to insulate against heat transfer (e.g., the thermal break 219) and / or flex (e.g., door / drawer gaskets and an interior panel of the doors) can be formed from or comprise a polymer material such as polyvinyl chloride (PVC) or acrylonitrile butadiene styrene (ABS). In some aspects, the various components can be formed from any other material, any of which can optionally be corrosion-resistant or replaceable for serviceability.

[0126] The various components of the appliance 100 can be formed from any one or more of a variety of manufacturing processes. For example and without limitation, the rail duct 205, the roof duct 206, and various other components of the air plenum system of the appliance 100 can be fabricated using subtractive manufacturing processes such as cutting and stamping. In some aspects, components can be made using machining and / or forging; additive manufacturing processes such as three-dimensional printing; and any other forming and assembly processes such as bending and riveting.

[0127] One should note that conditional language, such as, among others, “can,”“could,”“might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain aspects include, while other aspects do not include, certain features, elements and / or steps. Thus, such conditional language is not generally intended to imply that features, elements and / or steps are in any way required for one or more particular aspects or that one or more particular aspects necessarily comprise logic for deciding, with or without user input or prompting, whether these features, elements and / or steps are included or are to be performed in any particular aspect.

[0128] It should be emphasized that the above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Any process descriptions or blocks in flow diagrams should be understood as representing modules, segments, or portions of code which comprise one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included in which functions may not be included or executed at all, may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present disclosure. Many variations and modifications may be made to the above-described aspect(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.

Examples

Embodiment Construction

[0039]The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, and / or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and / or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0040]The following description is provided as an enabling teaching of the present devices, systems, and / or methods in their best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects described herein, while still obtaining the beneficial results of the present disclosure. It will also ...

Claims

1. A refrigerated appliance comprising:a refrigeration system, an evaporating unit thereof configured to supply air to an air plenum system of the appliance, the air plenum system configured to cool the appliance;a cabinet defining the air plenum system, the cabinet comprising:a first refrigerated portion defining a pan storage cavity configured to receive at least one food pan;a second refrigerated portion positioned below the first refrigerated portion and comprising;an insulated enclosure defining an interior surface and a base cavity configured to receive stored product;a duct received within the insulated enclosure and defining, at least in part, a communication air cavity, the communication air cavity being in fluid communication with each of the pan storage cavity and a return air cavity, the return air cavity being in fluid communication with the evaporating unit; anda worktop cavity defined in a worktop defined by the cabinet, the worktop defining at least in part the second refrigerated portion, the worktop cavity configured to receive a catch pan, the catch pan configured to be cooled by air inside the insulated enclosure.

2. The appliance of claim 1, wherein at least one of the first refrigerated portion and the second refrigerated portion further comprises a closure device configured to selectively cover and limit leakage of air from an ambient environment surrounding the appliance to and from one of the first refrigerated portion and the second refrigerated portion of the appliance.

3. The appliance of claim 1, wherein the pan storage cavity defines openings in a wall thereof, the openings configured to allow flow of air from the air plenum system into the pan storage cavity.

4. The appliance of claim 1, wherein the catch pan comprises a main panel and a first flange, the first flange extending from the main panel and angled with respect to the main panel.

5. The appliance of claim 4, wherein the catch pan further comprises a second flange, the second flange extending from the first flange and angled with respect to the first flange.

6. The appliance of claim 4, wherein at least a main panel of the catch pan is received within the worktop cavity and recessed below a top end of the worktop cavity.

7. The appliance of claim 1, wherein a bottommost surface of the catch pan is in contact with a panel of the appliance defining both an interior surface of the worktop cavity and an interior surface of the insulated enclosure.

8. The appliance of claim 7, wherein the panel of the appliance defines a single thickness of material.

9. The appliance of claim 7, wherein the panel is formed from a thermally conductive material.

10. The appliance of claim 1, wherein the catch pan comprises a handle configured to facilitate removal of the catch pan from the worktop cavity or reinsertion of the catch pan into the worktop cavity.

11. The appliance of claim 10, wherein the handle is positioned in a geometric center of the catch pan.

12. The appliance of claim 1, further comprising a cover configured to cover the catch pan when the catch pan is not in use.

13. The appliance of claim 12, wherein the cover is sized to be received at least partly within the worktop cavity.

14. The appliance of claim 1, further comprising a removable worktop support sized to fit on top of the worktop during use of the appliance.

15. The appliance of claim 1, wherein the worktop support is configured to support a food dish but also defines openings permitting passage of food ingredients through the worktop support and into the catch pan.

16. The appliance of claim 1, wherein the worktop comprises a thermal break extending between an interior panel of the worktop and an exterior panel of the worktop, the thermal break configured to minimize heat transfer into the appliance through the worktop cavity.

17. The appliance of claim 16, wherein the thermal break defines a shoulder configured to support the catch pan.

18. The appliance of claim 1, wherein the appliance comprises one and only one refrigeration system, which is the refrigeration system, the refrigeration system comprising one and only one compressor for cooling each of the first refrigerated portion, the second refrigerated portion, and the worktop cavity.

19. A method of using a refrigerated appliance comprising:inserting a catch pan into a rail comprising a worktop portion and a rail portion, the catch pan received within a worktop cavity defined within the worktop portion; andcooling the catch pan through cooling of an interior cavity of the appliance.

20. The method of claim 19, wherein cooling the catch pan comprises cooling the catch pan through conduction of heat from the catch pan to a panel of the appliance defining the interior cavity.

Images