Abstract:
A cold track plate which both secures the refrigeration coils to the exterior of the tray well and helps to distribute cooling (or absorb heat) more efficiently solves the problem of inconsistent heat transfer and other inefficiencies in pan cooler assemblies.

Description:
[0001]    This is a continuing application of provisional patent application No. 61/687,559 filed Apr. 27, 2012. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to improvements in the field of food processing equipment for properly and efficiently maintaining cold temperatures in a secure manner, and particularly to reduce the incidences of equipment failure and to provide a reliable equipment design which can withstand different operating conditions. 
       BACKGROUND OF THE INVENTION 
       [0003]    Commercially available chilling systems for open tray pans are both unreliable and inefficient. Most common designs rely upon the provision of a deep tray well which provides a space of about two inches beneath the bottom of the suspended pans and an air circulation system for utilizing air to pass over the portions of the tray well which are cool, lose sufficient heat to continue to be able to cool the other parts of the tray well and to then distribute the cold air to reduce the temperature of the pans suspended in the tray well. 
         [0004]    The problems with this arrangement are many. First, the air circulating fans cause cabinet designers to provide an independent source of electrical power to the volume within the tray well. Second, the electric fans consume electrical power, in addition to the power expended on operating the refrigeration system. Third the fans have an extremely cold environment and thus are likely to fail, and in a system which is dependent on both refrigeration flow and an air fan, failure of either causes a system failure. Fourth, where there is spillage into the tray well, the fans can be exposed and damaged. Fifth, the expanded size of the well that enables airflow, represents an expanded area for loss of cooling (absorption of surrounding heat) from a larger surface area. For example, considering a six inch wide well which is eight inches deep, produces an additional four linear inches (two on each side), and comparing to a six inch deep, six inch wide well having 18 wetted inches, four additional wetted inches equates to a 22% greater area in which heat losses can occur. 
         [0005]    In addition, conventional systems do not effectively concentrate the cooling over the surface of the well in such a way that will reliably assure that safe levels of food temperature will occur. Where the transfer of cooling in a tube is not effectively transferred to another structure, inefficiencies occur because heat is being absorbed at other places than through the pan well. In this case the refrigeration system may spend most of its energy refrigerating passive structures not related to the pan wells and the cost of cooling is expensive. Customers of food service equipment sellers often make complaints that food product did not stay consistently cold along the pan cooler well. Where a restaurant&#39;s temperatures are not maintained, spoiled food, sick customers and failing restaurant inspection ratings can result. 
         [0006]    What is needed is a system which will remedy the inefficiency inherent in most conventional pan cooler configurations. The needed system should enhance reliability by eliminating the need to depend upon air circulation, while at the same time eliminating the additional space that air flow normally occupies. The needed system should increase heat flow from the pan well, while eliminating as much as possible heat flow from other sources. The needed system should also facilitate overall pan well insulation. The needed system should also increase manufacturing reliability and reproducibility of efficient results, but without requiring a stringent set of design requirements. 
       SUMMARY OF THE INVENTION 
       [0007]    The provision of a cold track plate which both secures the refrigeration coils to the exterior of the tray well and helps to distribute cooling (or absorb heat) more efficiently was developed to solve the problem of inconsistent heat transfer and other inefficiencies in pan cooler assemblies. Cold track plating helps create the layout for easy installation of the refrigeration piping along the sides of the pan cooler well assembly. This not only speeds up the installation of the completed assembly, but it guarantees a uniform placement of the cooling coil piping. The present invention overcomes the tendency for human error in the placement of refrigeration tubing. 
         [0008]    Further, the process and structures of the invention provide a cold track plating that is in direct contact with the round refrigeration coil and is also connected to the flat side of the exterior of the pan cooler well. Traditionally, only a very small part of the refrigeration tube was touching any flat surface, which was not enough contact to effectively keep product cool. The process and configuration of the invention increases the total area that can be cooled, requiring less work from the refrigeration system which increases the overall efficiency. A cold track plate is made from sheets of aluminum by providing radiused bends in the material which are sufficient to place about half of the area of the circular cross section refrigeration piping closely aligned with and radially inward of the radiused bends of the cold track plate. 
         [0009]    In addition, a thermal mastic may be preferably employed between the refrigeration piping and the providing radiused bends in the material to help the cold track plate to play a significant role in terms of its ability to both absorb cooling (reject heat) and to spread that ability over a wider area. The circular cross section refrigeration piping touching the pan cooler well will transfer cooling (reject heat) as well, but over a much more limited area. Thermal mastic between the circular cross section refrigeration piping and pan cooler well exterior may also aid in heat transfer, but the size and area of close contact that the cold track plate presents to the exterior surface of the pan cooler well is a more significant factor. It has been found that a temperature of at least thirty-two to thirty-four degrees Fahrenheit may be sufficient for a pan cooler well as many applications and food types will not allow an internal temperature of the middle of the six inch pan to exceed and forty degrees Fahrenheit. It has been found that glycol in a refrigerated coolant system will enable achievement of this goal. 
         [0010]    The process involves selecting a sheet of heat conductive material, such as aluminum and providing a series of radiused bends of sufficient depth that the areas of flat heat conductive material between the radiused bends can overlie external surfaces of the pan cooler well. By way of an example, a refrigeration piping system made of copper will be used, as well as the example of a pan cooler well which is significantly longer than wide and which can accommodate six inch by six inch by six inch pans also known as “one sixth” pans will be used for example. The overall size of the sheet of heat conductive material having the radiused bends formed will depend upon both the size of the external surfaces of the pan cooler well and upon the configuration and size and spacing of the refrigeration piping to be used. It has been found that three-eights of an inch works well as a size for cooling coils, or refrigeration piping, and that a spacing of one and one-half inches taken from center to center of the refrigeration piping works well for most commercial restaurant pan cooler well applications. 
         [0011]    Contemplating a pan cooler well which can hold eight of the six inch pans, the most important surfaces to apply the cold track plates are the two major length sides. The second most important surface is the pan cooler well bottom. The latter most important surfaces to apply the cold track plates are the two end sides which may be about six inches wide apiece. Insuring that the ends of the pan cooler well are covered may be more of a function of whether there is an unusually hot wall adjacent one or both of the endmost pan cooler wells. Normally the pans, which are aligned in a row, easily receive enough cooling by virtue of being near the side wall and bottom of the pan cooler well, and also being adjacent a pan which is expected to be at the same temperature. 
         [0012]    Beginning the installation of the process and device of the invention, a series of pan cooler wells are typically welded together using “U” shaped spacers to that later installation of a covering finish mask will be facilitated. The series of connected pan cooler wells are inverted so that the outer external area of the pan cooler wells are exposed. The constructor is free to choose a pathway of refrigeration piping, as well as the axial length (taken with respect to the axial length of the refrigeration piping it will support). For a major side along a forty eight inch pan cooler well, a single length of cold track plate can be used, or a series of shorter length of cold track plate can be used. Where a supply of cold track plates may be provided in shorter length it may become a standard item. The overall routing of the refrigeration piping does not depend upon the cold track plate. Further, a series of abutting cold track plates may perform as well or nearly as well as a single long cold track plate. 
         [0013]    Once the cold track plates are selected, a user may drill holes, preferably mid-way between the two radiused areas to engage a threaded member and to secure the cold track plate closely in contact with the exterior of the pan cooler wells. In the alternative, the holes may be pre-formed in the cold track plates at the time that the radiused bends forming the hemispherical troughs are formed in the cold track plates. Holes of a diameter of about three eighths of an inch may be used. As by example, where a five inch high cold track plate is to be formed with four radiused hemispherical troughs (seen as radiused bends when viewed into the cross section), an eight inch high length of plating would be required so that the five inch height of the cold track plating with four radiused troughs would result. 
         [0014]    A series of threaded studs have to be attached to the exterior of the pan cooler wells. The studs are typically installed using an electrical stud gun which attaches a stud, typically a brass threaded stud into a location which will align with the holes in the cold track plates used to hold the cold track plates against the exterior of the pan cooler wells. Depending upon the capability of the stud gun, the studs may be attached to the the exterior of the pan cooler wells using the cold track plate holes as a guide. The assembler may provide a distribution header from which the copper refrigeration piping will attach and may provide a collection header from which the copper refrigeration piping will return the refrigerant after having passed through the refrigeration piping, the refrigerant having absorbed heat from the pan cooler well both directly and through the radiused bends of the cold track plate. 
         [0015]    Once the refrigeration piping is bent to the desired configuration enough that a cold track plate can be placed against the refrigeration piping to be secured to the exterior of the pan cooler well using the cold track plate holes and the studs applied to the exterior of the pan cooler well, a thermal mastic may be applied to the troughs of the cold track plate which will overlie the refrigeration piping. Whether additional thermal mastic will be applied on the flat areas of cold track plate will depend upon the characteristics of the thermal mastic as well as which other considerations were at hand. Then the cold track plates are more securely attached to the exterior of the pan cooler using washers. Lock washers which are hand tightened have been found to work well. 
         [0016]    Next, the areas of refrigeration piping which are not covered by the cold track plate are considered. In most cases the resulting area may be negligibly small. In other instances, a non-linear length of cold track plate may be constructed, such at the corners of the pan cooler well, for example. For the ends of the pan cooler well, a short axial length (taken with respect to the axial length of the refrigeration piping it will support) may be provided for each end of the pan cooling well. If it is thought that the passive flow of cooling at (heat absorption by) the ends is negligible, the constructor may leave the ends free of both lengths of refrigeration piping and cold track plate. As an example, an elongate structure can be covered by lengths of refrigeration piping by a long serpentine pattern, or by spiraling around the structure (and thus necessitating refrigeration piping and covering cold track plates at the ends. Many patterns are possible. 
         [0017]    Next, one of the most important aspects of the cold track plate occurs as it takes covering insulation externally to insulate the cold track plate from the outside environment along with areas of the pan cooler well which are exposed. Also insulated are any exposed areas of the refrigeration piping not otherwise underneath the cold track plate. The degree to which refrigeration piping extends over lengths not covered by the cold track plate is a function of user choice, the ability to provide cold track plate over shapes and length refrigeration piping which would otherwise be exposed, as measured against time and effort and cost. In further steps, the pan cooler is completed in the style of a cabinet or stand as further insulation and other structures are added to cause it to be of good use in a restaurant environment. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    The invention, its configuration, construction, and operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which: 
           [0019]      FIG. 1  is a side view of a pan cooler well which illustrates one possible layout of refrigeration piping utilizing the cold track plate of the inventive process and device; 
           [0020]      FIG. 2  is a sectional end view of the pan cooler well of  FIG. 1  and which illustrates the close relationships of the pan cooler well, refrigeration piping and cold track plate of the inventive process and device; and 
           [0021]      FIG. 3  is a closeup a sectional end view of the pan cooler well of  FIG. 1  which schematically illustrates heat flow; and 
           [0022]      FIG. 4  a more magnified view of  FIG. 3  illustrating further details thereof. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0023]    Referring to  FIG. 1 , a side view of a pan cooler  21  which may have an enclosing support  23 , a pan cooler well  25  seen closest to the viewer, and a drain for draining any moisture which occurs within the pan cooler well  25 . The surface of the pan cooler well  25  seen is an exterior surface. A length of refrigeration piping  31  is seen at the top left side of the exterior of the pan cooler well  25  and its is shown uncovered. As it is seen to extend to the right, it extends underneath a cold track plate  35  and specifically under a radiused first trough  37  as it extends to the right. Immediately above the first trough  37 , the cold track plate  35  ends, such as where further extension might interfere with an upper structure  39 . 
         [0024]    The refrigeration piping  31  extends the whole length of the cold track plate  35 , and emerging at a first turn  41  where the refrigeration piping  31  turns and extends back into the cold track plate  35  underneath a second trough  45 . As the refrigeration piping  31  extends back to the left, again the whole length of the cold track plate  35 , and emerging at a second turn  47  where the refrigeration piping  31  turns and extends back into the cold track plate  35  underneath a third trough  49 . As the refrigeration piping  31  extends back to the right, again the whole length of the cold track plate  35 , and emerging at a third turn  53  where the refrigeration piping  31  turns and extends back into the cold track plate  35  underneath a fourth trough  55 . The refrigeration piping  31  continues to extend to the left until it emerges from underneath the cold track plate  35  and proceeds around the left side of the pan cooler well  25  and out of sight. 
         [0025]    At the extreme left and right sides of  FIG. 1 , are see a first end  61  of the pan cooler well  25  and a second end  63  of the pan cooler well  25 . At the ends  51  and  63 , some loop extents of the refrigeration piping  31  are seen which may also be turns and which refrigeration piping  31  may also be secured with cold track plate  35 . Also seen are a series of nuts  71  which secure cold track plate  35  to the pan cooler well  25 , especially at flat areas  75  of the cold track plate  35  which lie in between the trough areas  37 ,  45 ,  49 , and  55 . Along the lower edge of the cold track plate  35 , an extension edge  77  is seen extending beyond the trough  55 . This extension edge  77  is used to transmit cooling (heat absorption) beyond the immediate region of the trough areas  37 ,  45 ,  49 , and  55 , and if it were practical to cover every square inch of a pan cooler well  25 , that would be optimum, however, the cold track plate  35  is provided to achieve coverage with economy of time and money. The extension edge  77  should be planned for and utilized with the tolerances and capabilities of the constructor in mind. 
         [0026]    Referring to  FIG. 2 , all three of the pan cooler wells  25  in a pan cooler  21  are seen in a sectional view, as well as a version of the cold track plate  35  having only three troughs which surround three lengths of refrigeration piping  31 . As can be seen, the pan cooler well  25  can be fairly closely spaced. A threaded shaft  81  is shown in phantom within of the series of nuts  71  which secure cold track plate  35  to the pan cooler well  25 . Drain  27  of each of the pan cooler wells  25  is shown as being connected. 
         [0027]    An insulation material  83  can be applied to the exterior of any and preferably all of the pan cooler wells  25  in forming the finished pan cooler  21 . The advantages include (1) passive areas not covered by the cold track plate  35  will be insulated and thus act as more efficient passive cold sinks, (2) insulation of the exterior surfaces of the cold track plate  35  will serve to prevent heat loss from those areas of the pan cooler wells  25  covered by the cold track plate  35 , and (3) attack of any of the (typically) copper refrigeration piping  31  by corrosive atmospheric influences from food, particularly citric acids will be blocked even more fully than any portions which might be coated by the thermal mastic to be shown in  FIG. 4 . 
         [0028]    Referring to  FIG. 3 , a further closeup view of the leftmost of the pan cooler wells  25  seen in  FIG. 3  is illustrates and emphasizes more clearly the existence of a cold track plate  35  having only three troughs (of which only troughs  37  and  49  are seen, the middle trough  45  being obscured by the drain  27 . Also shown are arrows indicating head flow into the cold track plate  35  and refrigeration piping  31  from within the pan cooler well  25 . 
         [0029]    Referring to  FIG. 4 , a further closeup view of the leftmost of the pan cooler wells  25  seen in  FIGS. 2 &amp; 3  is seen and illustrates and emphasizes more clearly the degree to which a cold track plate  35  can surround refrigeration piping  31 . Also seen is an extension edge  77  at the top of the cold track plate  35 . It is preferable to arrange coverage of the cold track plates  35  so that any pairs of extension edges  77  can cover as much area between them as possible without overlapping. Also seen in the upper part of  FIG. 4  as a black material between the refrigeration piping  31  and the inside of the trough  37  of the cold track plate  35  is a thermal mastic material which is preferably primarily applied between piping  31  and cold track plate  35 , but may be applied elsewhere. 
         [0030]    While the present invention has been described in terms of a device and system used for providing more efficient pan cooler assemblies by providing a better way to extract heat from a pan cooler well through refrigeration piping, and in particular a new structure which helps guide the configuration and insulation of a cooling device, the techniques employed herein are applicable to a wide range of devices and methods. 
         [0031]    Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art.