Abstract:
A refrigerated merchandiser comprising an insulated cabinet defining a product zone and having an air cooling and circulating system for maintaining product zone temperatures, the insulated cabinet including a vertical section defining one side of the product zone, an interior frame for structurally supporting the vertical cabinet section, and a load-bearing external frame assembly for supporting the entire insulated cabinet including an external vertical frame located on the outside of the vertical cabinet section and being secured to the interior vertical frame.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to the commercial refrigeration art, and more particularly to improvements in structural frame assemblies for food product merchandisers. 
     2. Description of Prior Art 
     Great advances have been made in the last forty years in the field of commercial food merchandising with improved insulation materials, better refrigerants, more efficient air handlers and condensing unit systems, better lighting and the universal use of ambient air temperature and humidity control in food stores and the like. A long checklist of important factors influence the construction and manufacture of food merchandisers including refrigeration requirements and performance, structural engineering for strength, durability and safety as well as insulation effect, servicing capability, product merchandising potential, and both manufacturing and operating costs. 
     In today&#39;s marketplace a wide variety of food merchandisers are used to best market different types of food products as well as meet their cooling needs. In the low temperature field, frozen food merchandisers maintain product display temperatures at about 0° F. and ice cream cases operate at about -5° F. to &#39;10° F. Frozen foods are best protected in reach-in coolers (with glass front doors), but open front, multi-deck merchandisers best display various food products. Similarly, in the medium temperature field of 28° F. to 50° F. product temperature range, glass front deli merchandisers are generally preferred for the marketing of freshly cut meats, cheeses, prepared salads and other deli items, but open front multi-deck merchandisers are widely used for packaged meat and dairy products and single deck cases are preferred for fresh produce. Even with some industry standardization at eight (8&#39;) foot and twelve (12&#39;) foot lengths for merchandisers, the manufacture of each commercial refrigerator fixture has remained a hand built operation. 
     Each type of commercial refrigerated merchandiser in the past largely has been individually designed for a specific food display or storage purpose, and fabrication generally has been a custom assembly process. These prior art merchandisers have had bulky internal frame assemblies with normally heavy insulation positioned to span between the frame members and form an integral part of the inner cabinet cooling system. Commercial merchandisers conventionally use evaporator coils of the fin and tube type, which in the past have extended the full length of the merchandiser as was thought necessary to best achieve even, balanced air flow distribution for uniform air cooling from end-to-end throughout the length of the display area. It has been discovered that modular external support frame structures can effectively support most commercial merchandiser cabinets--whether single deck as in deli and produce types, or 2-5 multi-deck cases for frozen foods, fresh meats or dairy products. The modularity of such external frame structures of the present invention is accommodated by the use of shortened vertical length internal struts that only need to support the weight of insulated panels and duct forming members, and which, in turn, can accommodate a novel modular evaporator coil concept as disclosed more fully in a commonly assigned patent application of John A. Behr entitled Refrigerated Merchandiser With Modular Evaporator Coils and EEPR Control, co-pending herewith. The supporting frame structure of the present invention will accommodate conventional full length evaporator coil construction and placement as well as the newer modular coil concepts. 
     SUMMARY OF THE INVENTION 
     The invention is embodied in a refrigerated food merchandiser having an insulated cabinet with a product zone and having an air cooling and circulation system for maintaining product zone temperatures, the insulated cabinet including a vertical section defining one side of the product zone, an interior vertical frame for structurally supporting the vertical cabinet section, and a load-bearing external frame assembly for supporting the entire insulated cabinet including an external vertical frame located on the outside of the vertical cabinet section and being secured to the interior vertical frame. 
     It is a principal object of the present invention to provide a novel modular external frame structure that facilitates the modular design and fabrication of different commercial refrigerated merchandisers, that provides a full length, heavy duty base frame and internal and external frame sections, that accommodates different air cooling systems of conventional and modular design, that has a novel insulated cabinet panel system, and that accommodates ease of manufacture, installation and service. These and still other objects and advantages will become more apparent hereinafter. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     In the accompanying drawings which form a part of this specification and wherein like numerals refer to like parts wherever they occur: 
     FIG. 1 is a perspective view, partly broken away, illustrating an open front multi-deck merchandiser embodying the invention, 
     FIG. 2 is an exploded view of the base and external frame assembly of the FIG. 1 embodiment, 
     FIG. 3 is an exploded view of the insulated cabinet assembly and air cooling features of the FIG. 1 embodiment, 
     FIG. 4 is an end elevational view of the FIG. 1 merchandiser, 
     FIG. 5 is an enlarged view of the external frame assembly, as taken substantially along line 5--5 of FIG. 4, 
     FIG. 6 is a greatly enlarged fragmentary perspective view, partly broken away, showing an insulated cabinet panel with imbedded frame mounting means, 
     FIG. 7 is an enlarged fragmentary cross-sectional view of a typical cabinet back panel and air duct assembly, and 
     FIGS. 8-12 are diagrammatic cross-sections of different sized merchandisers embodying the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     For disclosure purposes it will be understood that the modular structural frame assembly of the present invention is shown as applied in different commercial food display cases or merchandisers of the type installed in a typical supermarket. Such display cases are generally fabricated in standard eight (8&#39;) foot and twelve (12&#39;) foot lengths, but may be arranged in a multiple case line-up of several merchandisers operating in the same general temperature range. Low temperature refrigeration maintains display area temperatures of about 0° F. for frozen foods and medium temperature refrigeration maintains fresh food product area temperatures in the range of about 34° F. (red meat) to about 46° F. (produce). It is clear that the nature and thickness of insulation are design factors for low temperature and medium temperature merchandisers. It will also be understood that various commercial air cooling and control systems may be employed in the refrigerated merchandisers of the present invention, and do not form a direct part thereof. 
     FIGS. 1-7 illustrate a preferred embodiment of the invention in which an open front merchandiser M basically comprises an upper insulated cabinet assembly C and a lower or external frame assembly F. The merchandiser M of FIG. 1--as selected for disclosure purposes--is a depiction of a four-deck display merchandiser having an eight (8&#39;) foot length and operating at medium temperature for the refrigerated display of packaged fresh red meat. The cabinet assembly C is typical of open front merchandisers in that it has a bottom section 10, a back or rear wall section 11, a top wall section 12, a short front wall section 13, and an end wall closure 14, thus defining a product display area or zone 15 accessible through the front opening (at 16) extending between the top wall section 12 and front wall section 13. The cabinet assembly C also houses air cooling and circulation means for maintaining design temperatures in the product zone 15, and which comprises air moving plenums 17 with one or more fans 18 (located in the bottom section 10), and evaporator coil means 19 (located in the back section 11). Air circulation in rear duct 20 in the rear wall section 11 and top duct 21 in the top wall section 12 distribute cold exit air from the evaporators 19 to a discharge honeycomb 22 from which a refrigerated air curtain is formed across the open front 16 and returned through a return air duct 23 in the front wall section 13 and bottom duct 24 in the bottom wall section 10 to the air moving plenums 17 for recirculation. 
     The modular evaporator coils 19 as disclosed--while of conventional fin and tube configuration--constitute an advance in the commercial merchandiser field and are standardized in modular four (4&#39;) foot lengths to accommodate more flexibility in placement and use with the modular framing of the present invention, as disclosed more fully in the commonly assigned and co-pending patent application of John A. Behr entitled Refrigerated Merchandiser With Modular Evaporator Coils and EEPR Control, previously referenced herein. 
     A principal feature of the present invention resides in the external structural frame F and its modularity for adoption and use on an entire line of commercial merchandisers. The external frame assembly comprises a base section B and a vertical section V, as shown best in FIG. 2. The base section has at least two longitudinal frame or rail members 26 which extend horizontally substantially the full length of the merchandiser M. The base section also includes at least two transversely extending horizontal frame or strut members 27 (three being shown in FIG. 2) which are rigidly secured to span across the longitudinal rails 26 to form a heavy duty floor frame or base mounting means for the entire merchandiser M. Front and back vertical frame or riser members 28 are constructed and arranged at the front and back of each horizontal strut 27 to extend upwardly a predetermined distance for the selected cabinet assembly C to thereby locate the top of its front wall 13 at the appropriate elevation for shopper convenience in accessing the product zone 15. The mating edges of the horizontal struts 27 and vertical risers 28 are angle cut, at 29, and welded to form transverse unified U-shaped base frame subassemblies with the longitudinal rails 26. In the preferred embodiment, these frame members are channel-shaped, at 30, with a &#34;hat&#34; cross-section having outward extending flanges 31. The tops of the bottom channel wall 28a of each riser 28 is notched, at 28b, to receive a horizontal frame member 32 of the vertical section V, and the upper side walls 28c of the risers 28 are predrilled, at 33, for mating alignment with similar predrilled holes 34 and assembly with the frame members 32. 
     A vertical section V is provided for each transverse base frame subassembly (27, 28). Each vertical section V of the external frame assembly F, in addition to its horizontal frame or leg members 32, includes a vertical frame or leg member 35 also of channel-shaped hat section (30) having a bottom wall 35a and opposed side walls 35b with outward flanges 36. As shown best in FIG. 5, the horizontal frame leg 32 and the vertical frame leg 35 are unified by a pair of similar opposed triangular wedge braces 37 positioned in side-by-side relationship between the opposed side walls 35b of the vertical leg 35 and the opposed side wall 32b of the horizontal leg 32. Each brace 37 has a triangular side wall 38 with vertical and horizontal flanges 38a and 38b for engagement with and attachment to the vertical bottom wall 35a of vertical frame member 35 and the horizontal bottom wall of horizontal flange member 32. Thus, the horizontal frame leg 32 and the vertical frame leg 35 of the vertical section V are rigidly secured together. 
     It will now be clear that the base section B is constructed and arranged to form a horizontal support structure with vertical stanchions or risers 28 selected to establish the desired cabinet elevation. The vertical section V is rigidly secured to the base section B and forms a horizontal cabinet supporting seat on its flanges 32b for the cabinet bottom wall 10 which has a molded insulated shell 40 with a sculpted or angled rearward edge 40a complementary to the angle of the brace member side wall 38. It will also be clear that the vertical frame legs 35 of the longitudinally spaced vertical sections V are constructed and arranged for supporting abutment with the back wall section 11 of the merchandiser cabinet C. 
     Referring particularly to FIGS. 3, 6 and 7, the insulated cabinet C is constructed and arranged with a novel back wall and top wall assembly. A flat foamed outer or back insulated panel assembly 42 includes a lower vertical panel section 43 and an upper horizontal panel section 44. The lower back panel 43 may be formed in several modular sections 43a, 43b to establish the selected height for the merchandiser M. During the foaming formation of these panels (43, 44), frame mounting means 45 are molded into the panels. One embodiment of such mounting means 45 provides a dual-body fastener 46 with a connecting web 46a, and each body is molded around a through bolt 46b to form outwardly projecting threaded studs 47. As shown best in FIG. 6, the body portions 46 of the mounting means 45 have enlarged circumferential ends forming outer end surfaces 46b and inner lands 46c to thereby oppose stresses that would tend to displace or move the mounting means or break the panel. The essence of the studded mounting means 46, 47 is for it to be constructed and arranged to be embedded within the foam panel and rigidly held in place therein. The back wall and top wall assembly also includes interior frame means 48 for structural support and which includes a vertical back panel leg 49 and a horizontal top panel leg 50. In FIG. 3 it will be seen that interior frame means 48 at the merchandiser ends comprises a single transverse I-beam member 49a, 50a having longitudinally extending back flanges 49b, 50b whereas an intermediate frame means 48 has dual beam walls and flanges. As will be apparent to those skilled in the commercial refrigeration art, the front flanges are constructed in a typical manner with vertically spaced slots (not shown) to adjustably receive shelf supporting brackets (not shown) for projecting into the display area 15 and mounting product shelving (not shown) thereon. The display area 15 is defined at its back by at least one inner vertical panel 52, which may have plural sections 52a and 52b corresponding to the vertical height requirements of the merchandiser M. The top of the display area is defined by at least one horizontal top panel 53. 
     Clearly, the internal frames 49 are assembled on the threaded studs 47 that inwardly project from the outer back panel 43, and the top panel 53 is similarly provided with mounting stud means to secure to the interior frame horizontal beam 50. The inner and top panels 52, 53 are secured between the corresponding sets of internal frame members 49, 50, and the top wall 12 is completed by a canopy structure 54 that includes an upper (outer) insulated panel 54a and which carries a lighting canopy 55 and the like, in FIG. 1. 
     The prior art merchandiser construction typically employed full height and depth structural end frames interconnected by full length structural pieces as part of the cabinet, and thus the full length evaporator coil configurations of the prior art were accommodated between the end frames in front of the insulated back wall structure. In the present invention, the inner and outer panels 52, 43 of the back wall section 11 are mounted on the internal vertical frame members 49, which are spaced longitudinally in four (4&#39;) foot placement to accommodate the modular coils 19 therebetween so that there will be one intermediate interior frame member 49 in an eight (8&#39;) foot merchandiser and two intermediate frame members 49 in a twelve (12&#39;) foot merchandiser. The vertical height of the internal frames 49 is predetermined to overlap the vertical dimension of the external vertical frame members 35 and provide a rigid structural connection therebetween by the fasteners 45 in the rear panel 43. It will be seen that the vertical internal frame members 49 are assembled on one side of the outer panel 43 and bolted onto the studs 47, and this section is then attached to the vertical external frame members 35 which receive the outwardly projecting studs 47 from the opposite (outer) panel side. The inner panel 52 can then be assembled on the internal frame members 49. Clearly, the canopy 54 and top wall section 12 are assembled on the internal frame members 50, and this weight, together with the additional weight of loaded product shelving, is carried by the vertical internal frame members 49 to the external vertical frame assembly V and thence to the base assembly B. 
     Referring now to FIGS. 8-12, it will be seen that the modular frame structure F of the present invention is applicable to an entire line of merchandisers. In FIG. 8, a single deck produce merchandiser M-1 has a cabinet C-1 with a short back wall section 111 and no top wall, and the cabinet C-1 is assembled on the modular external frame F-1 with the cabinet bottom wall section 110 being disposed on the horizontal frame members 132 with the back wall section 111 abutting and attached to the vertical frame members 135. FIG. 9 illustrates a two-deck merchandiser M-2 with its higher profile cabinet C-2 (including top wall section 212) being assembled on modular frame F-2 in the same manner previously described. FIG. 10 shows a three-deck merchandiser M-3 with cabinet C-3 and external frame F-3; FIG. 11 shows a four-deck merchandiser M-4 with cabinet C-4 and external frame F-4; and FIG. 12 shows a five-deck merchandiser M-5 with cabinet C-5 and external frame F-5. It will be noted that the taller merchandisers M-4 and M-5 utilize longer (higher) vertical external frame members 435, 535 thereby providing adequate lateral attachment and support of the corresponding internal frame members (not shown). Further, the vertical outer and inner panels 43 and 52 and horizontal top wall panels 44 are made up in different modular sizes to selectively adjust the height and depth of the product area for the respective merchandisers. It will also be seen that the height adjustment riser members 528 of the five-deck merchandiser M-5 are shortened to thereby keep the overall vertical profile of the product display area fully accessible to shoppers. 
     The scope of the invention is intended to encompass such changes and modifications as will be apparent to those skilled in the art, and is only to be limited by the scope of the appended claims.