Pallet Airflow Spacer Layout for Uniform Warehouse Cooling
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Solution Overview
Problem
Existing warehouse freezer systems face inefficiencies in heat transfer due to irregular spacers that allow airflow to spill and fail to provide consistent cooling, leading to uneven temperature distribution and potential blockages from drooping cases.
Innovation Solution
The use of planar palletized product spacers with longitudinal airflow channels and adjustable air dams to ensure unidirectional airflow and maintain consistent temperature across all layers of palletized products, combined with lateral spacers to prevent direct abutment and ensure fluid communication between pallet assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If irregular spacers are used to separate palletized products, then airflow can move freely between layers, but airflow spillage occurs and heat transfer efficiency decreases
Solution Approach 1:
The spacer is divided into multiple planar segments with defined airflow channels, creating structured pathways that guide airflow directionally while preventing random spillage. The segmentation of the spacer into inlet and outlet regions with intermediate walls creates controlled flow zones.
Solution Approach 2:
The planar spacer acts as an intermediary element between product layers, mediating airflow by providing structured channels rather than allowing direct uncontrolled movement. The spacer's intermediate walls and defined pathways serve as mediators that direct airflow efficiently.
2Ease of manufacture
If irregular spacers are used, then cases can be stacked without precise alignment, but temperature distribution becomes uneven
Solution Approach 1:
Different regions of the spacer have different functions: inlet regions receive airflow, intermediate walls direct flow, and outlet regions distribute flow to adjacent pallets. This local differentiation ensures uniform temperature distribution while maintaining stacking flexibility.
Solution Approach 2:
The spacer introduces a new dimensional structure with vertical walls and horizontal channels that create three-dimensional airflow pathways. This dimensional structure ensures consistent cooling across multiple layers while allowing flexible stacking arrangements.
3Device complexity
If air dams are not used, then the system structure is simpler, but airflow spillage occurs reducing cooling effectiveness
Solution Approach 1:
Air dams are positioned in advance at strategic locations within the spacer structure to prevent airflow spillage before it occurs. The preliminary placement of these barriers ensures that airflow remains contained and directed throughout the cooling process.
Solution Approach 2:
The air dams convert potential harmful airflow spillage into beneficial directed airflow by strategically blocking escape paths and redirecting flow through productive channels. What could be seen as an added complexity actually solves the spillage problem efficiently.
4Area of stationary object
If lateral spacers are not used, then pallet assemblies can abut directly saving space, but fluid communication between pallets is blocked
Solution Approach 1:
Lateral spacers are nested within the overall pallet assembly structure, allowing them to maintain fluid communication pathways while occupying minimal space. The spacers are integrated into the design rather than added as external elements, optimizing space utilization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances heat transfer efficiency by maintaining consistent airflow and temperature distribution, preventing airflow spillage, and ensuring uniform cooling or heating of products, thereby improving food safety and storage efficiency.
Implementation Method 1
Air handlers, e.g., chillers provided in the interior of warehouse produce conditioned, e.g., cold air and maintain the temperature of ambient air within the warehouse space at a desired temperature... Freezing air is drawn through air pathways within the palletized product
Implementation Method 2
The plurality of spacers are formed of a material having a thermal conductivity of at least 3 W/m·K, at least 5 W/m·K, or at least 10 W/m·K so that the spacers are operable to effect heat transfer with product contained in cases
Data Source
AI summary
Systems and methods for airflow management around palletized cases of goods in a warehouse storage facility are provided, in which airflow around each individual layer of cases is facilitated while airflow “spillage” around the sides, top or bottom of pallet assemblies is minimized or eliminated. One exemplary device for such airflow management includes palletized product spacers disposed between respective layers of vertically stacked cases, in which the product spacers facilitate a substantially unidirectional longitudinal airflow. Another exemplary airflow management device is a series of automatically adjustable air dams disposed at the tops of respective pallet assemblies which prevent air spillage and establish intermediate air manifold spaces. Yet another device is a lateral pallet spacer prevents direct abutment of the side surfaces of neighboring pallet assemblies and thereby ensures that the air manifold spaces are in fluid communication with the spacers of multiple pallet assemblies.