Composite refrigeration unit

Abstract

The present disclosure provides a temperature controlled composite body for the transportation and storage of goods which are required to be maintained at certain temperatures. The composite body includes embedded piping containing phase change material so that the cooling system of the composite body is contained within the composite body itself rather than an external system.

Description

COMPOSITE REFRIGERATION UNITCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to U.S. Provisional Patent Application Serial No. 63 / 528,962, filed July 26, 2023, and entitled “COMPOSITE REFRIGERATION UNIT” (Attorney Docket No.: WNC-2021-12-01-US), the complete disclosure of which is expressly incorporated by reference herein.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates generally to composite structures and temperature control units. More particularly, the present disclosure relates to composite structures with embedded temperature control mechanisms. Such composite structures may be used for construction of cargo truck bodies, vans, trailers, storage units, or other structures where temperature control is desired.BACKGROUND OF THE DISCLOSURE

[0003] Cargo vehicles are used in the transportation industry for transporting many different types of cargo. Certain cargo vehicles may be refrigerated and insulated to transport temperature-sensitive cargo. Cargo vehicles may be constructed using composite materials, which may lead to an absence of or reduction in metallic and wood materials and associated advantages, including simplified construction, thermal efficiency, reduced water intrusion and corrosion, and improved fuel efficiency through weight reduction, for example.

[0004] The mounting of a temperature control unit to a cargo vehicle, such as a refrigerated truck body, requires the consideration of such a load, including the structural integrity for general movement of the vehicle and moments of extreme movement of the vehicle, for example, during a sudden stop. Conventional mounting techniques within composite vehicles require at least some destruction of the integrity of the composite material and may require unfavorable placement of stress loading and / or expensive and time-intensive manufacturing techniques. As such, there is a need to support a refrigeration unit on a cargo vehicle in a manner that preserves the structural integrity of the wall or panel on which it is supported.SUMMARY OF THE DISCLOSURE

[0005] The present disclosure provides a temperature controlled composite body for the transportation and storage of goods which are required to be maintained at certain temperatures. The composite body includes embedded piping containing phase change material so that the cooling system of the composite body is contained within the composite body itself rather than an external system.

[0006] In a first aspect of the present disclosure a refrigeration assembly for a cargo vehicle is disclosed. The refrigeration assembly comprises a coolant vessel defined by a first material layer, a second material layer, and an open volume between the first material layer and the second material layer. The refrigeration assembly also comprises a phase-change material configured to be received within the open volume, where the phase-change material has a phasechange temperature determined by at least one parameter of the cargo vehicle.

[0007] In a second aspect of the present disclosure, a cargo body for a cargo vehicle is disclosed. The cargo body comprises a first side wall, a second side wall, a rear door assembly coupled to the first and second side wall, and a front wall coupled to the first and second side wall. The front wall includes an outer portion and an inner portion. A refrigeration assembly is included on at least a portion of the front wall and comprising a phase-change coolant material configured to be received between the outer portion of the front wall and the inner portion of the front wall.

[0008] In various aspects of the disclosure, the refrigeration assembly may further comprise an insulation material surrounding the open volume. The insulation material may be a foam core material.

[0009] In various aspects of the disclosure, the coolant vessel may define at least a portion of a front wall of a cargo body of the cargo vehicle. The coolant vessel may define an entirety of the front wall.

[0010] In various aspects of the disclosure, the coolant vessel may be defined by a plurality of preforms. The first material layer may define an outer surface of a portion of the cargo vehicle and the second material layer may define an inner surface of the portion of the cargo vehicle.

[0011] In various aspects of the disclosure the refrigeration assembly may further comprise at least one fluid conduit configured to receive the phase-change material. The at leastone fluid conduit may be in fluid communication with the open volume. The open volume may be defined by a rigid fluid passageway fluidly coupled to the at least one fluid conduit. The at least one fluid conduit may define the open volume.

[0012] In various aspects of the disclosure, the coolant vessel may be defined by a plurality of preforms, the first material layer may define an outer surface of the preforms and the second layer may define an inner surface of the preforms.

[0013] In various aspects of the disclosure, at least one of the first material layer and the second material layer may be comprised of a fiber-reinforced material.

[0014] In various aspects of the disclosure, at least one of the first material layer and the second material layer may be comprised of aluminum.

[0015] In various aspects of the disclosure, the outer portion and the inner portion may each be defined by a fiber-reinforced polymer.

[0016] In various aspects of the disclosure, the front wall may be comprised of a plurality of preforms and an outer surface of each of the preforms may define the outer portion of the front wall, an inner surface of each of the preforms may define the inner portion of the front wall, and the phase-change coolant material may be received between the outer and inner surfaces of each preform. Each preform may define an open volume between the outer and inner surface thereof, and the open volume may be configured to receive the phase-change coolant material. The open volume of each preform may be generally a cylindrical shape. The refrigeration assembly may include a first plurality of fluid conduits, and the open volume of each preform may be configured to receive at least one fluid conduit surrounded by the phase-change coolant material. Each fluid conduit of the first plurality of fluid conduits may include a fluid passageway configured to receive a refrigeration fluid. The refrigeration assembly may include at least one collector tube fluidly coupled to the fluid conduits. The refrigeration assembly may include a second plurality of fluid conduits which may be configured to receive the first plurality of fluid conduits. Each fluid conduit of the second plurality of fluid conduits may include a fluid passageway configured to receive the phase-change coolant material.

[0017] In various aspects of the disclosure, the phase-change coolant material has a phase-change temperature determined by at least one parameter of the cargo vehicle. The phasechange coolant material may be an engineered phase-change material.

[0018] Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrative embodiments exemplifying the best mode of carrying out the invention as presently perceived.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The foregoing aspects and many of the intended advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description when taken in conjunction with the accompanying drawings.

[0020] FIG. 1 is a perspective view of a cargo vehicle having a cargo body having a floor assembly, a roof, right and left sidewalls, and a front wall or nose;

[0021] FIG. 2 is a cross-sectional view of the right sidewall of FIG. 1, the right sidewall being formed of composite material;

[0022] FIG. 3 is a perspective view of a nose of a cargo vehicle, the nose being formed of composite material and including an embedded tube infrastructure;

[0023] FIG. 4 is a perspective view of a lateral preform of the nose of FIG. 3, the lateral preform being formed of composite material and including an embedded tube assembly;

[0024] FIG. 5 is a lateral cross-sectional view of the lateral preform of FIG. 4;

[0025] FIG. 6 is a lateral and longitudinal cross-sectional view of the lateral preform ofFIG. 5;

[0026] FIG. 7 is a cross-sectional view of the embedded tube assembly of the lateral preform of FIG. 5;

[0027] FIG. 8 is a perspective view of a longitudinal preform of the nose of FIG. 3, the longitudinal preform being formed of composite material and including an embedded collector tube;

[0028] FIG. 9 is a longitudinal cross-sectional view of the longitudinal preform of FIG.8;

[0029] FIG. 10 is a perspective view of a tube infrastructure embedded within the nose of FIG. 3;

[0030] FIG. 11 is a cross-sectional view of the nose of FIG. 3;

[0031] FIG. 12 is a schematic of a cooling system of the cargo vehicle of FIG. 1; and

[0032] FIG. 13 is a flowchart illustrating a method for controlling an internal temperature of the cargo vehicle of FIG. 1 using the cooling system of FIG. 12.

[0033] Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of various features and components according to the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present disclosure. The exemplification set out herein illustrates an embodiment of the invention, and such an exemplification is not to be construed as limiting the scope of the invention in any manner.DETAILED DESCRIPTION OF THE DRAWINGS

[0034] For the purposes of promoting an understanding of the principals of the invention, reference will now be made to the embodiments illustrated in the drawings, which are described below. The embodiments disclosed below are not intended to be exhaustive or limit the invention to the precise form disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. It will be understood that no limitation of the scope of the invention is thereby intended. The invention includes any alterations and further modifications in the illustrative devices and described methods and further applications of the principles of the invention which would normally occur to one skilled in the art to which the invention relates.1. Cargo Vehicle

[0035] Referring initially to FIG. 1, a cargo vehicle 100 is shown for supporting and transporting cargo. The illustrative straight frame vehicle 100 extends along a longitudinal axis L I from a front end 102 to a rear end 104 and includes a motorized truck 106 that powers a plurality of wheels 108 or other traction devices, a chassis 110, and a bumper assembly 120. The illustrative vehicle 100 further includes a cargo body 130 having a floor assembly 140 for supporting cargo, a roof 150, right and left sidewalls 160R, 160L, a front wall or nose 170, and a rear door assembly 180 having a rear frame 182 and a door (not shown) to access the cargo body 130.

[0036] In the illustrated embodiment of FIG. 1, cargo body 130 is an enclosed body that is supported atop chassis 110. Cargo body 130 may be refrigerated and / or insulated to transport temperature-sensitive cargo. While the concepts of this disclosure are described in relation to a refrigerated truck body, it will be understood that they are equally applicable to other vehicles generally, and more specifically to refrigerated van semi-trailers, dry freight trailers, including dry freight van semi-trailers, other commercial box trailers, and the like. Accordingly, those skilled in the art will appreciate that the present invention may be implemented in a number of different applications and embodiments and is not specifically limited in its application to the particular embodiments depicted herein.2. Composite Panels

[0037] Cargo body 130 may be constructed, at least in part, of composite panels. For example, the floor 140, roof 150, right and left sidewalls 160R, 160L, and / or nose 170 of the composite cargo body 130 may be constructed of composite materials. As such, the floor 140, roof 150, right and left sidewalls 160R, 160L, and / or nose 170 of the composite cargo body 130 may be referred to herein as composite panels. Each composite panel may be a single, unitary component, which may be formed from a plurality of layers permanently coupled together. Exemplary composite materials for use in the composite cargo body 130 include fiber-reinforced polymers or plastics (FRPs), for example glass-fiber-reinforced polymers or plastics (GFRPs) and carbon-fiber-reinforced polymers or plastics (CRPs).

[0038] A laminated composite right sidewall 160R is shown in cross-section in FIG. 2. Those skilled in the art will appreciate that the following teachings related to the right sidewall 160R may also be applied to the floor 140, roof 150, left sidewall 160L, and / or nose 170 of the composite cargo body 130. With respect to the composite floor 140, in particular, details of the construction may be found US Patent No. 10,829,163, the disclosure of which is hereby incorporated by reference in its entirety.

[0039] The illustrative sidewall 160R of FIG. 2 includes a core layer 200, an outer skin layer 210 that faces outwardly from the cargo body 130 (FIG. 1) toward the surrounding environment, and an inner skin layer 220 that faces inwardly toward the cargo in cargo body 130 (FIG. 1). Each of these laminated layers 200, 210, 220 is described further below.

[0040] Referring still to FIG. 2, the core layer 200 of the composite sidewall 160R may include one or more structural supports or preforms 202. Exemplary preforms 202 for use in core layer 200 include PRISMA ® preforms provided by Compsys, Inc. of Melbourne, Florida. Each preform 202 may include an inner foam core 204, an intermediate layer 206, and an outer FRP layer 208, each of which is described further below.

[0041] The inner foam core 204 of each preform 202 may include a self-expanding, selfcuring structural foam material. Suitable foams include polyurethane foams, such as a methylene-diphenyl-methane diisocyanate (MDI) based rigid polyurethane foam, for example.

[0042] The outer FRP layer 208 (which may be referred to herein as the "first" FRP layer 208) of each preform 202 may include a polymer matrix reinforced with fibers configured to enhance the structural properties of the surrounding polymer matrix. Suitable reinforcing fibers include glass fibers, carbon fibers, aramid fibers (e.g., Kevlar® fibers available from DuPont Protection Technologies of Richmond, Virginia), linear polyethylene or polypropylene fibers (e.g., Spectra® fibers available from Honeywell International Inc. of Morris Plains, New Jersey), or polyester fibers. The reinforcing fibers may be present in fabric form, which may be mat, woven, or knit, for example. Exemplary fabrics include chopped fiber fabrics, such as chopped strand mats (CSM), and continuous fiber fabrics, such as 0790° fiberglass fabrics, +457-45° fiberglass fabrics, +607-60° fiberglass fabrics, 0° warp unidirectional fiberglass fabrics, and other stitched fiber fabrics, for example. Exemplary fabrics are commercially available from Vectorply Corporation of Phenix City, Alabama and include the E-LM 1810 fiberglass fabric with 0° unidirectional fibers, the E-LTM 3610 fiberglass fabric with 0790° fibers, and the EL TM 2408 fiberglass fabric with 0° / 90° fibers, for example. Such fabrics may have an area density of about 800 g / m2to about 1,500 g / m2or more.

[0043] The intermediate layer 206 of each preform 202 may serve as a transition layer for coupling the inner foam core 204 to the outer FRP layer 208. The intermediate layer 206 may be sufficiently porous to at least partially receive foam from the adjacent foam core 204 and the polymer matrix from the adjacent FRP layer 208. The intermediate layer 206 may be a nonwoven fabric with continuous or chopped fibers.

[0044] The individual preforms 202 of the core layer 200 may be designed to accommodate the needs of the particular application. For example, in areas of the final structure requiring more strength and / or insulation, a low-density foam core 204 may be replaced with ahigh-density foam core 204 or a hard, plastic block. The individual preforms 202 of the core layer 200 may also be sized, shaped, and arranged in a manner that accommodates the needs of the particular application. For example, in areas of the final structure requiring less strength (for example, most areas of the roof 150), the preforms 202 may be relatively large in size, with the foam cores 204 spanning relatively large distances before reaching the surrounding layers 206, 208. By contrast, in areas of the final structure requiring more strength (for example, most areas of the floor 140), the preforms 202 may be relatively small in size, with the foam cores 204 spanning relatively small distances before reaching the surrounding layers 206, 208. Stated differently, the preforms 202 may be shaped as relatively wide panels in areas of the final structure requiring less strength and as relatively narrow support beams in areas of the final structure requiring more strength.

[0045] Referring still to FIG. 2, the outer skin layer 210 of the composite sidewall 160R may include a FRP layer 212 and an outer gel coat 214. The FRP layer 212 (which may be referred to herein as the "second" FRP layer 212) may be similar to the above-described first FRP layer 208, including a polymer matrix reinforced with suitable reinforcing fibers. According to an exemplary embodiment of the present disclosure, a plurality of different reinforcing fiber layers may be stacked together and used in combination to form the FRP layer 212. For example, a chopped fiber fabric (e.g., CSM) may be positioned adjacent to a continuous fiber fabric. In this stacked arrangement, the chopped fibers may help support and maintain the adjacent continuous fibers in place, especially around comers or other transitions. Also, the chopped fibers may serve as a web to resist column-type loads in compression, while the adjacent continuous fibers may resist flange-type loads in compression. Adjacent reinforcing fiber layers may be stitched or otherwise coupled together to simplify manufacturing, to ensure proper placement, and to prevent shifting and / or bunching. The outer gel coat 214 may be a polymer- rich or polymer-only layer that provides a smooth outer finish in a desired color.

[0046] Referring still to FIG. 2, the inner skin layer 220 of the composite sidewall 160R may include a FRP layer 222 and an optional inner gel coat 224. The FRP layer 222 (which may be referred to herein as the "third" FRP layer 222) may be similar to the above-described first and second FRP layers 208, 212, including a polymer matrix reinforced with suitable reinforcing fibers. The inner gel coat 224 may be a polymer-rich or polymer-only layer similar to the abovedescribed outer gel coat 214 that provides a smooth inner finish in a desired color.

[0047] During manufacturing, the composite panels of the present disclosure, including the composite sidewall 160R of FIG. 2, may be formed by a layered molding process. An exemplary molding process involves (1) applying a gel-coat resin onto a mold surface to form the outer gel coat 214, (2) layering the reinforcing fibers of the outer FRP layer 212, the preforms 202 of the core layer 200, the reinforcing fibers of the inner FRP layer 222, and any other desired layers onto the outer gel coat 214, (3) wetting out the layers 212, 200, 222, and any other applied layers with at least one laminating resin to impregnate and / or coat the fibers, (4) optionally applying another gel-coat resin onto the layers 212, 200, 222 to form the inner gel coat 224, and (5) curing the materials upon the mold surface (either sequentially and / or simultaneously) to form a single, integral, laminated composite sidewall 160R. In some embodiments, the composite panels of the present disclosure may be manufactured using a continuous manufacturing process.3. Cargo Body Nose for Trailer Refrigeration Unit

[0048] FIG. 3 illustrates a composite structure, such as composite nose 170 as discussed above. Although the composite structure of FIG. 3 is discussed in terms of composite nose 170, the composite structure as described herein may also apply to any other composite structure, including right sidewall 160R, floor 140, roof 150, and left sidewall 160L of composite cargo body 130. The teachings may further apply to other composite bodies pertaining to vehicles, buildings, and the like.

[0049] Composite nose 170 includes a plurality of preforms 302 similar to those discussed above, including lateral preforms 302a and longitudinal preforms 302b. Lateral preforms 302a are positioned laterally relative to a height H of composite nose 170 between longitudinal preforms 302b, which are positioned along the height H of composite nose 170 as illustrated in FIG. 3 and discussed further herein.

[0050] Now referring additionally to FIGS. 4-6, a singular preform 302a is illustrated. As with the preforms 202 described above, lateral preform 302a includes a core layer 200, an intermediate layer 206, and an outer FRP layer 208 as described above. A refrigeration tube, such as outer tube 304, is embedded within the inner foam core 204 of core layer 200 during manufacturing of preform 302a, with an inner tube 306 positioned within outer tube 304 to form a lateral tube assembly 305. Outer tube 304 extends along a length L2 of the correspondinglateral preform 302a. Inner tube 306 also extends along the length L2 of the corresponding lateral preform 302a and may include extensions 307, which extend beyond one or both ends 320 of the corresponding lateral preform 302a to facilitate coupling of inner tube 306 to longitudinal preform 302b as described further herein. A phase change material 308 is contained within outer tube 304 surrounding inner tube 306. Outer tube 304 may not extend beyond the ends 320 of the corresponding lateral preform 302a so that outer tube 304 is fully contained within the corresponding lateral preform 302a. In other words, phase change material 308 within outer tube 304 is maintained within corresponding lateral preform 302a, i.e., phase change material 308 does not exit the outer tube 304 in which it is deposited.

[0051] Phase change material 308 may be engineered to maintain certain phases, i.e., solid or liquid, at desired predetermined temperatures. Phase change material 308 may be a gellike material or another known material, such as water. Preferably, phase change material 308 exhibits a solid-to-solid, solid-to-gel, and / or gel-to-gel phase transition to mitigate leaks of the phase change material into the inner foam core 204 of preform 302a by maintaining a generally consistent density and therefore a generally consistent volume and composite structure weight. In freight carriage applications, this prevents change in load of the cargo body, for example. This also omits the need for expandable / contractable piping upon the phase change of the phase change material. Other known phase change materials known in the art, including, e.g., water or other solid-to-liquid phase change materials, may also be considered and used. Phase change material 308 preferably has a high latent heat that stores and releases large amounts of heat when melting or freezing, respectively. The volume of phase change material within a composite structure is dependent on the desired use and corresponding thermal requirements of the corresponding composite structure.

[0052] Outer tube 304 is illustratively formed of a polymer material having a low coefficient of thermal conductivity to facilitate insulation of phase change material 308. The inner foam core 204 of core layer 200 further serves as insulation of phase change material 308. Inner tube 306 is illustratively formed of a metallic material having a high value coefficient of thermal conductivity, e.g., copper, aluminum, brass, steel, bronze, etc., and contains a refrigerant fluid 310, such as glycol or another refrigerant fluid. As mentioned above, inner tube 306 is illustratively concentric with outer tube 304 so that the refrigerant fluid 310 passes through phase change material 308, allowing for efficient heat transfer between refrigerant fluid 310 and phasechange material 308, i.e., so that phase change material 308 efficiently removes heat energy from the refrigerant fluid.

[0053] Referring again to FIG. 3 and additionally to FIGS. 8-9, each inner tube 306 of each corresponding lateral preform 302a fluidly couples with at least one collector tube 312 of a corresponding longitudinal preform 302b. As illustrated, composite nose 170 includes two longitudinal preforms 302b, one positioned on each end of aligned and parallel lateral preforms 302a, and each of the longitudinal preforms 302b includes an embedded collector tube 312.

[0054] Referring specifically to FIGS. 8-9, longitudinal preforms 302b, collector tube 312 is embedded within inner foam core 204 of the corresponding longitudinal preform 302b along the height H of the corresponding longitudinal preform 302b and composite nose 170; inner foam core 204 may serve as insulation to collector tube 312 and contained refrigerant fluid 310. Collector tube 312 includes extensions 311 which extend beyond one or both of ends 314 of the corresponding longitudinal preform 302b to a valve 316 for circulation of the refrigerant fluid 310 as described further herein. A plurality of apertures 318 extend in series between each end 314 of longitudinal preform 302b along a side 322 of the longitudinal preform 302b. Each aperture 318 is configured to receive an end of an inner tube 306 to couple each inner tube 306 to collector tube 312 and place inner tube 306 in fluid communication with collector tube 312. In other words, the number of apertures 318 formed within longitudinal preform 302b may correspond with the number of inner tubes 306 and / or number of lateral preforms 302a within composite nose 170.

[0055] Now referring to FIGS. 10-11, when assembled, each of the inner tubes 306 is fluidly coupled to collector tubes 312 so that the refrigerant fluid 310 (FIGS. 5-7) can flow through each of the inner tubes 306 and / or collector tubes 312. In other words, refrigerant fluid 310 is capable of circulating throughout composite nose 170 and corresponding cooling system of cargo body 130 (FIG. 1), as further described herein.

[0056] Composite nose 170 is generally manufactured via molding process as described above in Section 2. During formation of the lateral preforms 302a, lateral tube assembly 305 of each lateral preform 302a is included within the mold and inner foam core 204 fdls the lateral preform 302a around said lateral tube assembly 305. Similarly, during formation of the longitudinal preforms 302b, collector tube 312 is included within the mold and inner foam core 204 fills the longitudinal preform 302b around said collector tube 312. The extensions 307 ofinner tube 306 are inserted into a corresponding aperture 318 of longitudinal preform 302b to couple with collector tube 312 in a fluid-tight manner to facilitate leak-free flow / circulation of refrigerant fluid 310 (FIGS. 5-7) between the inner tube 306 and the collector tube 312. This is repeated for each lateral preform 302a and its corresponding lateral tube assembly 305 with each corresponding longitudinal preform 302b until the composite structure is assembled. The lateral preforms 302a and longitudinal preforms 302b are laminated to form a single composite structure as described above in Section 2. In some embodiments, the assembled preforms 302 may be sprayed with a polyester resin, which is then cured to solidify and create a laminate, skinlike cover over the assembled preforms 302 to form a single composite structure. As such, the phase change material 308 is contained within the interior of the composite structure and does not need to be refilled or replaced.

[0057] The structure of the composite structure, e g., as described herein allows for the assembled preforms to provide support to the lateral tube assembly 305 and corresponding phase change material 308 and refrigerant fluid 310 within the walls, floor, and / or roof of the composite structure. In other words, the weight of the phase change material 308, refrigerant fluid 310, and corresponding tube assemblies is distributed over at least a portion of the composite structure to facilitate equal support of the refrigeration assembly throughout the composite structure.

[0058] While the disclosure above and further herein describes the cooling system and method in terms of composite materials and composite structures, it is recognized that other materials may be used for construction of the refrigeration assembly. For example, polymeric or metallic materials, such as aluminum or other metallic materials capable of defining the described structure, may be assembled to contain an insulation material, such as a foam material, an inner tube, an outer tube, refrigerant fluid, and phase change material as described further herein.4. Cooling System and Method for Refrigerated Composite Body

[0059] Now referring to FIG. 12, a cooling system 400 including composite nose 170 is illustrated. As discussed above, each extension 311 of collector tube 312 (Fig. 11) includes a valve 316 for selective operation and flow of refrigerant fluid 310 into and / or out of the corresponding collector tube 312 and composite structure. For example, during use, i.e., whencargo body 130 is being used enroute and / or for storage of chilled goods or when another composite structure is being used for temperature-controlled storage or other use, hoses 402a may be used to couple collector tubes 312 to an internal heat exchanger 404. A pump 406 may be operated to pump freshly chilled refrigerant fluid 310 from first collector tube 312 to internal heat exchanger 404 for cooling of cargo body 130. Refrigerant fluid 310 may then be pumped from internal heat exchanger 404 to second collector tube 312. Refrigerant fluid 310 is then pumped through the lateral preforms 302a via corresponding inner tubes 306, where phase change material 308 chills refrigerant fluid 310 as it flows through the inner tubes 306 due to the thermally conductive material of the inner tubes 306 as described above. As such, a flow circuit is formed via cooling system 400.

[0060] Internal heat exchanger 404 may include, for example, a finned tube heat exchanger, a fan arranged with a plurality of tubes containing the chilled refrigerant fluid to blow air by said plurality of tubes to chill the air and thereby the interior of the cargo body or other composite structure, a radiator, and / or another heat exchanger capable of functioning to fulfill the purpose of internal heat exchanger 404 as described herein, i.e., to use the freshly chilled refrigerant fluid to control the temperature of a cargo body or other composite structure.

[0061] In some embodiments, cooling system 400 may further include a controller 407 operatively coupled to internal heat exchanger 404 and / or pump 406 and a thermal sensor 408 operatively coupled to controller 407. Thermal sensor 408 is configured to measure the internal temperature of cargo body 130 or other corresponding composite stmcture and transmit said internal temperature to controller 407. Controller 407 is configured to compare the current internal temperature to one or more predetermined target or threshold temperatures to determine operation of cooling system 400 as described further herein. In other embodiments, cooling system 400 does not include a controller and / or a thermal sensor 408 and pump 406 and / or internal heat exchanger 404 continually operates while cooling system 400 is active, i.e., until cooling system 400 is manually shut off or is put in a charging mode as described further herein.

[0062] Referring additionally to FIG. 13, method 500 for cooling cargo body 130 or another composite structure using cooling system 400 (FIG. 12) including controller 407 and thermal sensor 408 is illustrated. At box 502, thermal sensor 408 detects the internal temperature of cargo body 130 and transmits said internal temperature to controller 407. Controller 407 compares the internal temperature to a first predetermined temperature threshold, i.e., a targettemperature, at box 504. If the internal temperature is above the first predetermined temperature threshold, pump 406 and / or internal heat exchanger 404 is operated to chill the interior of cargo body 130 at box 506 and the thermal sensor 408 and controller 407 continue monitoring of the internal temperature. If, at box 504, the internal temperature is at or below the first predetermined temperature threshold, pump 406 and / or internal heat exchanger 404 cease or do not start operation at box 508.

[0063] If method 500 reaches box 508, thermal sensor 408 then detects the internal temperature of cargo body 130 and transmits said internal temperature to controller 407 at box 510. Controller 407 compares the internal temperature to a second predetermined temperature threshold, i.e., a grace temperature, at box 512. If the internal temperature is above the second predetermined temperature threshold, pump 406 and / or internal heat exchanger 404 is operated to chill the interior of cargo body 130 at box 514 and thermal sensor 408 and controller 407 continue monitoring of the internal temperature at box 502. If, at box 512, the internal temperature is at or below the second predetermined temperature threshold, pump 406 and / or internal heat exchanger 404 cease or do not start operation at box 516 and thermal sensor 408 and controller 407 continue monitoring of the internal temperature at box 510. The second predetermined temperature may generally be a temperature higher than the first predetermined temperature that is still an acceptable temperature for cargo body 130. In some embodiments, the second predetermined temperature and the first predetermined temperature may be the same; in other words, rather than moving from box 508 to box 510 and box 512, method 500 may return from box 508 to box 502. As illustrated, method 500 is cyclical and continues as long as cooling system 400 is operational, i.e., until cooling system 400 is manually shut off or placed in a charging mode as described further herein.

[0064] Phase change material 308 (FIGS. 4-7) provides cooling to the refrigerant fluid 310 (FIGS. 4-7) throughout a work cycle of the vehicle (i.e., cargo body 130) or other composite structure, such as during a delivery route or chilled storage event. During the work cycle, the heat exchange between the phase change material and the refrigerant fluid causes the phase change material to warm from its solid or frozen phase toward a liquid / gel or molten phase. Referring again to FIG. 12, hoses 402b may be used to couple collector tubes 312 to an external heat exchanger 410 via extensions 311 to recharge the phase change material, or, in other words, chill the phase change material toward and / or to a solid or frozen phase. In a charging mode,external heat exchanger 410 is coupled to collector tubes 312 as described above. Refrigerant fluid 310 is pumped from a first collector tube 312 to external heat exchanger 410 for cooling of refrigerant fluid 310, which is then pumped from external heat exchanger 410 to second collector tube 312. Freshly chilled refrigerant fluid 310 is then pumped through lateral preforms 302a via corresponding inner tubes 306, where refrigerant fluid 310 chills the phase change material 308 due to the thermally conductive material of inner tubes 306 as described above. As such, a flow circuit is formed. The charging mode as described herein may optionally be used during off-peak windows to allow for low-cost power usage during operation of external heat exchanger 410.

[0065] As discussed above, each extension 311 includes a valve 316 that may be selectively opened / closed to allow for selective flow of refrigerant fluid 310 into and / or out of collector tubes 312. As such, if hoses 402a are coupled to fewer than all extensions 311 of composite nose 170, valves 316 of the unused extensions 311 may be maintained in a closed position while valves 316 of the used extensions 311 may be maintained in an open position to allow flow of refrigerant fluid 310 through hoses 402a. Likewise, if hoses 402b are coupled to fewer than all extensions 311 of composite nose 170, valves 316 of the unused extensions 311 may be maintained in a closed position while valves 316 of the used extensions 311 may be maintained in an open position to allow flow of refrigerant fluid 310 through hoses 402b.

[0066] Composite nose 170 as described herein, along with other similar composite structures including right sidewall 160R, floor 140, roof 150, and left sidewall 160L of composite cargo body 130 and / or other composite bodies pertaining to vehicles, buildings, and the like, may be free from conventional refrigeration units, which makes the corresponding composite body lighter and gives the corresponding composite body a more sleek design. Additionally, because conventional refrigeration units require the use of engines, composite bodies according to the teachings provided herein reduces engine exhaust emissions, reduces noise, and requires less energy for operation. Reduction or elimination of use of conventional refrigeration units further mitigates road hazards such as fires resulting from overheating refrigeration unit engines and reduction or elimination of additional fuel tanks that must be carried on the vehicle for operation of said engines.

[0067] While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the inventionusing its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practices in the art to which this invention pertains.

Claims

WHAT IS CLAIMED IS:

1. A refrigeration assembly for a cargo vehicle, comprising: a coolant vessel defined by a first material layer, a second material layer, and an open volume between the first material layer and second material layer; and a phase-change material configured to be received within the open volume, where the phase-change material has a phase-change temperature determined by at least one parameter of the cargo vehicle.

2. The refrigeration assembly of claim 1, further comprising an insulation material surrounding the open volume.

3. The refrigeration assembly of claim 2, wherein the insulation material is a foam core material.

4. The refrigeration assembly of claim 1, wherein the coolant vessel defines at least a portion of a front wall of a cargo body of the cargo vehicle.

5. The refrigeration assembly of claim 4, wherein the coolant vessel defines an entirety of the front wall.

6. The refrigeration assembly of claim 1, wherein the coolant vessel is defined by a plurality of preforms.

7. The refrigeration assembly of claim 6, wherein the first material layer defines an outer surface of a portion of the cargo vehicle and the second material layer defines an inner surface of the portion of the cargo vehicle.

8. The refrigeration assembly of claim 1, further comprising at least one fluid conduit configured to receive the phase-change material.

9. The refrigeration assembly of claim 8, wherein the at least one fluid conduit is in fluid communication with the open volume.

10. The refrigeration assembly of claim 9, wherein the open volume is defined by a rigid fluid passageway fluidly coupled to the at least one fluid conduit.

11. The refrigeration assembly of claim 8, wherein the at least one fluid conduit defines the open volume.

12. The refrigeration assembly of claim 1, wherein the coolant vessel is defined by a plurality of preforms, the first material layer defines an outer surface of the preforms and the second material layer defines an inner surface of the preforms.

13. The refrigeration assembly of claim 1, wherein at least one of the first material layer and the second material layer is comprised of a fiber-reinforced material.

14. The refrigeration assembly of claim 1, wherein at least one of the first material layer and the second material layer is comprised of aluminum.

15. A cargo body for a cargo vehicle, comprising: a first side wall; a second side wall; a rear door assembly coupled to the first and second side wall; a front wall coupled to the first and second side wall, and the front wall including an outer portion and an inner portion; and a refrigeration assembly included on at least a portion of the front wall and comprising a phase-change coolant material configured to be received between the outer portion of the front wall and the inner portion of the front wall.

16. The cargo body of claim 15, wherein the outer portion and the inner portion are each defined by a fiber-reinforced polymer.

17. The cargo body of claim 15, wherein the front wall is comprised of a plurality of preforms, an outer surface of each of the preforms defines the outer portion of the front wall, and an inner surface of each of the preforms defines the inner portion of the front wall, and the phase-change coolant material is received between the outer and inner surfaces of each preform.

18. The cargo body claim 17, wherein each preform defines an open volume between the outer and inner surface thereof, and the open volume is configured to receive the phase-change coolant material.

19. The cargo body of claim 18, wherein the open volume of each preform is generally a cylindrical shape.

20. The cargo body of claim 19, wherein the refrigeration assembly includes a first plurality of fluid conduits, and the open volume of each preform is configured to receive at least one fluid conduit surrounded by the phase-change coolant material.

21. The cargo body of claim 20, wherein each fluid conduit of the first plurality of fluid conduits includes a fluid passageway configured to receive a refrigeration fluid.

22. The cargo body of claim 21, wherein the refrigeration assembly includes at least one collector tube fluidly coupled to the fluid conduits.

23. The cargo body of claim 19, wherein the refrigeration assembly includes a second plurality of fluid conduits configured to receive the first plurality of fluid conduits.

24. The cargo body of claim 23, wherein each fluid conduit of the second plurality of fluid conduits includes a fluid passageway configured to receive the phase-change coolant material.

25. The cargo body of claim 15, wherein the phase-change coolant material has a phasechange temperature determined by at least one parameter of the cargo vehicle.

26. The cargo body of claim 23, wherein the phase-change coolant material is an engineered phase-change material.

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