Display case with insulated foam paneling

A refrigerated display case chassis includes a first insulated panel and a second insulated panel. The first insulated panel has a first foam layer bounded by a first pair of thermally conductive sheets. The first insulated panel forms a first wall of the refrigerated display case chassis. The second insulated panel has a second foam layer bounded by a second pair of thermally conductive sheets. The second insulated panel forms a second wall of the refrigerated display case chassis. The second insulated panel mates with the first insulated panel to form a thermally insulated joint where, in cross-section, one sheet of the first pair of thermally conductive sheets terminates at a surface of the second foam layer. The thermally conductive sheets have a greater thermal conductivity than the first or second foam layers.

FIELD OF THE DISCLOSURE

This disclosure relates to refrigerated enclosures, and particularly to methods and equipment for manufacturing foam panels used in refrigerated display cases.

BACKGROUND OF THE DISCLOSURE

Refrigerated enclosures are used in commercial, institutional, and residential applications for storing and displaying refrigerated or frozen objects. Refrigerated enclosures may be maintained at temperatures above freezing (e.g., a refrigerator) or at temperatures below freezing (e.g., a freezer). The walls or casing of refrigerated enclosures can be made with foam panels of different shapes and dimensions. Improvements in the methods and systems for manufacturing refrigerated display foam panels are sought.

SUMMARY

Implementations of the present disclosure include a refrigerated display case chassis. The refrigerated display case chassis includes a first insulated panel and a second insulated panel. The first insulated panel has a first foam layer bounded by a first pair of thermally conductive sheets. The first insulated panel forms a first wall of the refrigerated display case chassis. The second insulated panel has a second foam layer bounded by a second pair of thermally conductive sheets. The second insulated panel forms a second wall of the refrigerated display case chassis. The second insulated panel mates with the first insulated panel to form a thermally insulated joint where, in cross-section, one sheet of the first pair of thermally conductive sheets terminates at a surface of the second foam layer. The thermally conductive sheets have a greater thermal conductivity than the first or second foam layers.

In some implementations, one sheet of the second pair of thermally conductive sheets terminates at a surface of one of the first thermally conductive sheets.

In some implementations, the joint includes a half-lap joint with the one sheet of the first pair of thermally conductive sheets terminating at an internal surface of the second foam layer.

In some implementations, the first insulating panel forms a back wall of the refrigerated display case chassis and the second insulating panel forms a top of the refrigerated display case chassis.

In some implementations, the first insulating panel forms a top of the refrigerated display case chassis and the second insulating panel forms a back wall of the refrigerated display case chassis.

In some implementations, the joint includes an upper corner of the refrigerated display case chassis.

In some implementations, the refrigerated display case chassis further includes a third insulated panel that has a third foam layer bounded by a third pair of thermally conductive sheets. The third insulated panel forms a base of the refrigerated display case chassis. The first insulated panel attaches to the third insulated panel to form a second joint. In some implementations, the third insulated panel includes, in a side view, a non-flat cross-section. In some implementations, the third insulated panel includes a frame extending along side edges of the third insulated panel and defining a volume containing the foam layer. At least part of the frame is bonded to the foam layer during curing of the foam layer. In some implementations, the frame includes a cap bracket that extends along the length of the third insulated panel. The upper sheet of the pair of thermally conductive sheets of the third insulated panel includes a first tab extending away from an upper end of the upper sheet toward a lower sheet of the pair of thermally conductive sheets. The lower sheet includes a second tab extending away from an upper end of the lower sheet toward the upper sheet such that the bracket overlaps at least one of the tabs to form a seal with the tabs. In some implementations, the frame includes end caps defining, in side view, a cross section corresponding with a non-flat cross-section of the pair of thermally conductive sheets. The non-flat cross-section of the thermally conductive sheets includes two vertical surfaces and a horizontal surface extending between and connecting the two vertical surfaces.

Implementations of the present disclosure also include an insulated case. The insulated case includes a first insulated panel and a second insulated panel. The first insulated panel forms a first wall of the insulated case and includes a first foam layer sandwiched between a first pair of liners. The first foam layer defines, in cross section, a first foam edge. The second insulated panel forms a second wall of the insulated case and includes a second foam layer sandwiched between a second pair of liners. The second foam layer defines, in cross section, a second foam edge configured to interface with the first foam edge of the insulated foam back panel to form a thermally insulated joint.

In some implementations, the first foam edge includes a first non-flat foam edge and the second foam edge includes a second non-flat foam edge corresponding with the first non-flat foam edge. One of the first or second non-flat foam edge is arranged to receive the other of the first or second non-flat foam edge.

In some implementations, the first wall includes a back or side wall of the insulated case and the second wall includes a ceiling of the insulated case, and the thermally insulated joint includes a corner. In some implementations, the insulated case also includes a bracket including a vertical surface and a horizontal support surface, the horizontal support surface configured to support, with the bracket attached to the first insulated panel, the second insulated panel.

In some implementations, the first and second insulated panels are arranged along a common plain and the first foam edge includes a flat foam edge and the second foam edge includes a flat foam edge corresponding with the first flat foam edge. In some implementations, the first foam edge extends beyond a first edge of the first pair of liners a first distance to form a male interface. The second foam edge is offset from a second edge of the second pair or liners a second distance equal to the first distance to form a female interface. The insulated joint includes a male-female connection with the first foam edge inserted into the second insulated panel and terminating at the second foam edge.

In some implementations, the insulated case also includes an insulated base including a forward end and a rearward end opposite the forward end. The first insulated panel attaches to the rearward end of the insulated base.

Implementations of the present disclosure also include a method of assembling an insulated display case. The method includes positioning a first insulated panel on a base of the insulated display case to form a first wall. The first insulated foam panel includes a first foam layer sandwiched between a first pair of thermally conductive sheets. The method also includes attaching a second insulated panel to the first insulated panel to form a second wall of the insulated display case. The second insulated panel includes a second foam layer sandwiched between a second pair of thermally conductive sheets. Attaching the second insulated panel to the first insulated panel includes forming a thermally insulated joint where, in cross-section, one sheet of the first pair of thermally conductive sheets terminates at a surface of the second foam layer.

In some implementations, the method also includes forming the first insulated panel by placing a first liner on a top surface of a lower press tool. Forming the first insulated panel also includes positioning a frame at a top surface of the first liner, the frame bordering a volume defined between the top surface of the first liner and an interior surface of the frame. The frame includes one of i) a movable frame attached to the lower press tool, the movable frame including a non-stick coating, or ii) brackets configured to be part of the foam panel. Forming the first insulated panel also includes depositing a liquid resin on the first liner within the volume. The liquid resin contains a foaming agent that causes the liquid resin to expand within the volume such that the resin bonds to the top surface of the first liner. Forming the first insulated panel also includes pressing a second liner against the frame. The second liner overlays the first liner while the liquid resin expands and solidifies into a foam between and bonded to the first liner and the second liner.

Implementations of the present disclosure also include a method of forming a foam panel for a refrigerated assembly. The method includes placing a first liner on a top surface of a lower press tool. The method also includes positioning a frame at a top surface of the first liner. The frame borders a volume defined between the top surface of the first liner and an interior surface of the frame. The frame includes one of i) a movable frame attached to the lower press tool, the movable frame including a non-stick coating, or ii) brackets configured to be part of the foam panel. The method also includes depositing a liquid resin on the first liner within the volume, the liquid resin containing a foaming agent that causes the liquid resin to expand within the volume such that the resin bonds to the top surface of the first liner. The method also includes pressing a second liner against the frame. The second liner overlays the first liner while the liquid resin expands and solidifies into a foam between and bonds to the first liner and the second liner.

In some implementations, the frame includes a movable frame. The movable frame includes two longitudinal rails that extend parallel with respect to each other and two lateral rails that reside between the longitudinal rails and extend in a direction perpendicular with respect to the two longitudinal rails. At least one of the lateral rails is movable along a length of the longitudinal rails, changing a distance between the lateral rails and thereby changing a length of the volume defined by the frame. Positioning the frame on the top surface of the first liner includes placing the longitudinal rails and the lateral rails on the top surface of the first liner, forming a squared-shaped or a rectangular-shaped frame.

In some implementations, the method further includes, after pressing the second liner, removing the longitudinal rails and the lateral rails away from the foam, exposing the foam between the first liner and the second liner.

In some implementations, the frame is configured to move away from the top surface of the lower press tool to accommodate a thickness of the first liner. The lower press tool includes multiple actuators, at least one actuator of the plurality of actuators is connected to a respective rail and configured to move the respective rail. The method further including, before placing the first liner on the top surface of the lower press tool, moving the rails and making room for the first liner to be placed on the top surface of the lower press tool.

In some implementations, the frame includes the brackets configured to be part of the foam panel and the first liner includes a non-flat sheet-form liner. The method further includes placing two substantially straight longitudinal brackets on the first liner. The longitudinal brackets extend parallel to each other. The method also includes placing two lateral, non-flat brackets on the first liner with the lateral brackets extending between the longitudinal brackets and connecting opposite ends of the longitudinal brackets.

In some implementations, the upper press tool and the lower press tool each includes one or more vacuum channels at their respective surfaces. The vacuum channels are configured to flow air forming a suction effect thereby gripping a respective one of the first or second liner.

In some implementations, placing the first liner on the top surface of the lower press tool includes placing, by a robotic arm including an end of arm tool, the first liner. The end of arm tool includes a longitudinal frame and vacuum cups attached to the frame. The vacuum cups grip the first liner and release the first liner on the top surface of the lower press tool.

Implementations of the present disclosure include a manufacturing assembly that includes a nozzle and a press. The press includes a lower press tool including a top surface configured to support a first liner and including a frame configured to be supported on a top surface of the first liner. The frame borders a volume defined between the top surface of the first liner and an interior surface of the frame, the frame including one of 1) a movable frame attached to the lower press tool, the movable frame including a non-stick coating, or 2) brackets configured to be part of the foam panel. The press also includes an upper press tool movable with respect to the lower press tool. The nozzle is configured to deposit liquid resin on the first liner within the volume, the liquid resin containing a foaming agent that causes the liquid resin to expand within the volume such that the resin bonds to the top surface of the first liner. The upper press tool presses a second liner against the frame while the liquid resin expands and solidifies into a foam between the first liner and the second liner and bonds to the first line and the second liner.

In some implementations, the manufacturing assembly further includes a robotic arm that including an end of arm tool that includes a rectangular frame, and vacuum cups attached to the rectangular frame. The vacuum cups grip the first liner and release the first liner on the top surface of the lower press tool.

Implementations of the present disclosure may provide improvements in the manufacturing and installation process of refrigerated enclosures by simplifying the steps of making and using foam panels. For example, implementations of the present disclosure may provide improvements in the quality of foam panels. For example, implementations of the present disclosure can reduce discontinuities and reductions in the insulating material. Additionally, robustness of design (e.g., fewer component parts, simple but effective geometries for component parts and resultant sub-assemblies) drives more consistent and repeatable sub-assemblies. Consequently, higher first pass-yields may be experienced on sub-assemblies with lowered costs of re-work and scrap, and faster quality inspections. The configuration of the foam panels can help improve the seal quality, durability, and insulating properties of joints between foam panels. For example, because two foam panels attached together are designed to interface with each other and have uniform dimensions, the seal at a joint (e.g., a half-lap joint) between the two panels can be more uniform and consistent, reducing air infiltration into the case during operation. Furthermore, the manufacturing process described here and can help reduce time and resources that are typically required to manufacture foam panels using existing methods. Using a non-stick frame eliminates the need of using foam boards utilized in existing methods. Additionally, the design of the foam panels and the equipment described here can enable making foam boards of different shapes and sizes. Furthermore, the disclosed methods may allow a quicker conversion between products of differing dimensions (e.g., panel length, width, and height) and/or different interface geometries (e.g., half-lap, tongue-and-groove, etc.) in fulfilling a wider range of customer needs. Lastly, the use of End-Of-Ann-Tools, conveyors, and other automated techniques avoids handling damage to sub-assembly foam panels prior to processing into a display case chassis and avoids handling damage to thin-sheet panel liners prior their assembly into a foamed panel.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure describes insulated foam panels that improve the process of assembling and installing refrigerated enclosures. The present disclosure also describes methods and equipment for manufacturing the insulated foam panels. The foam panels are simple in design, include fewer parts than conventional foam panels, and have interfacing edges that allows refrigerated enclosures to be quickly assembled, while maintaining thermally insulative joints. The process of manufacturing such panels can employ an assembly line that includes a press. The press includes a lower panel tool and an upper panel tool that together press a pair of sheets or liners to sandwich, with the sheets, an expanding foam until the foam hardens to form the foam panel. To make flat foam panels, the press can use a non-stick movable frame to form a foam panel in which the foam layer is exposed. To make non-flat panels, such as tank foam panels, the press can use permanent plastic brackets to form all or part of the periphery of the foam layer.

The foam panels can be used for various products or building materials that require insulation, e.g., a refrigerated display case chassis, doors, wall panels, etc. For example, a refrigerated display case chassis is an assembly that includes a tank (e.g., a base where a commercial refrigerator display case sits), a canopy that extends above the refrigerator display, and a back panel or wall that connects the tank to the canopy. Each of these components can be made of one or more insulated foam panels.

FIG.1depicts a refrigerated display case chassis10. For example, the refrigerated display case chassis10can be part of any type of refrigerated display case11such as a refrigerator, a freezer, or other enclosure (or partial enclosure) defining a temperature-controlled space. Specifically, the refrigerated display case chassis10can form the base, back wall, and roof of the refrigerated display case. The refrigerated display case can have side walls (not shown) made of insulated foam panels or a different material. If configured as an open-front display case, the refrigerated display case may have a front sill structure (not shown) comprised of aesthetic panels and/or protective bumpers which deflect shopping carts, with unimpeded or open access above the front sill to the temperature-controlled space. If configured as a door-case (e.g., a closed case), the front area of the refrigerated display case may include one or more doors (not shown) for accessing the refrigerated or frozen objects within the temperature-controlled space.

The refrigerated display case chassis10has multiple insulated panels (e.g., foam panels)12,14,16that form the base, back wall, and top of the refrigerated display case. Specifically, the refrigerated display case chassis10has a base or tank panel16, a top or canopy panel12, and a back panel14connecting the tank and canopy panels16,12. The tank panel16can form the floor of the refrigerated display case, the back panel14can form the back wall of the refrigerated display case, and the top panel12can form the roof of the refrigerated display case.

The refrigerated display case chassis10has a length ‘l’, a depth ‘d’, and a height ‘h’ that are based on the design specifications of the refrigerated display case. For example, the refrigerated display case chassis10can have a length ‘l’, depth and height ‘h’ based on a desired storage volume of the refrigerated display case. Additionally, the refrigerated display case chassis10can have a length ‘l’ that accommodates one, two, or more refrigerated display case doors.

The length ‘l’ of the refrigerated display case chassis10can be the same or substantially the same as the length of the top panel12, the back panel14, and the tank panel16. Similarly, the depth ‘d’ of the refrigerated display case chassis10can be the same or substantially the same as the width of the top panel12and the tank panel16. Moreover, the height ‘h’ of the refrigerated display case chassis10can be the same or substantially the same as the height of the back panel14together with a height of a vertical portion17of the tank panel16.

The refrigerated display case chassis10also includes a base frame20and an upper frame13that includes middle brackets18, and side brackets19. The base frame20and the upper frame13can be made of metal, hard plastic, or a similar structural material. The tank panel16rests on the base frame20. The base frame20can have wheels22for moving the refrigerated display case chassis10. The side brackets19are attached to opposite sides of the chassis10and connect and support the three panels12,14,16. The side brackets19can be C-shaped bracket and the middle brackets18can be L-shaped brackets.

FIG.2shows an exploded view of the refrigerated display case chassis10. The framing of the refrigerated display case chassis10has two side brackets19and one, multiple, or, in implementations in which the width of the case is small enough, no middle brackets18. The side brackets have a base arm21, a vertical arm23extending upright from an end of the base arm21, and a top arm24extending from an upper end of the vertical arm21. The base arm21has a bottom edge that corresponds with the cross-section of the tank panel16.

The brackets18,19have a vertical back surface31and a horizontal top support surface33. The horizontal support surface33supports the top insulated panel12with the bracket attached to the back insulated panel14,

Both the back panel14and top panel12have a respective interface edge41,43that includes a non-flat end such as a notched end to form a half-lap joint. The interface edges41of the back panel14interfaces and corresponds with the interface edge43of the top panel12. Top and back panels12,14can be attached at their interfaces by an adhesive such as an epoxy or a silicone sealant.

FIG.3illustrates a side view of the refrigerated display case chassis10assembled. The vertical and top arms23,24of the brackets18,19can form a 90 degree angle, a smaller angle, or, as shown, an angle larger than 90 degrees such as 90.75 degrees. Similarly, the vertical and bottom arms23,21of the brackets18,19can form a 90 degree angle, a smaller angle, or, as shown, an angle larger than 90 degrees such as 92 degrees.

The tank panel16is attached to the back panel14to form a second joint32. The second joint32can be formed with a tape or sealant disposed between the two panels and with mechanical fasteners.

Referring also toFIGS.4and5, the top panel12has a foam layer44bounded by (e.g., sandwiched between) a lower sheet or liner42(e.g., a thermally conductive sheet) and an upper sheet or liner45(e.g., a thermally conductive sheet). The sheets42,45can be made of metal such as aluminum or stainless steel and can have a greater thermal conductivity than the foam layer44. In some implementations, the sheets42,45could also be made of other non-metallic materials (e.g., FR-4 fiberglass) that have a greater thermal conductivity than the foam layer44. The matting interface43is formed in the foam layer44of the panel12. For example, the notched edge is a foam edge that is directly attached to the foam edge of the back panel14. The notched edge can be formed during the curing process of the foam or can be cut after the foam cures (e.g., during trimming of the panel). The back panel14is similar to the top panel12and can be made with the same materials.

As shown inFIG.5and as further described in detail below with respect toFIGS.14-19, a flat insulated panel15(e.g., the back panel or the top panel) can be formed in a press such that edges46of the sheets42,45extend beyond the edge or periphery47of the foam layer44. After being formed in the press, the edges46can be trimmed so that the edges46are flush with the edge47of the foam layer44. Specifically, the flat foam panels can be trimmed along the edge of the hardened foam layer to provide, when assembled together, a precise fit between the foam panels. During trimming, a longitudinal notch can be cut on the edge or periphery of the foam layer to make, with the other panel, a half-lap joint. Cutting the longitudinal notch may include further cutting a portion of one of the sheets to be flush with the edge of the notched foam.

FIG.6shows a detail, cross-sectional view taken along line6-6inFIG.3, showing a front, upper edge30of the tank panel16. The upper edge30is disposed adjacent the lower arm21of the C-shaped bracket19. As further described in detail below with respect toFIGS.11-13, the tank16has a cap bracket74(e.g., an M-shaped longitudinal breaker) that overlaps a tab82of the lower sheet70of the tank16and is disposed under a tab88of the upper sheet80. The bracket74can include a tape50or sealant that attached to a component of the refrigerated display case such as a frame of a door.

The tank foam panel16also has end caps76(e.g., end breakers or side caps) on each end of the panel16. The end or side caps76form an edge of the tank panel16and include a reinforcement core58(e.g., a honeycomb core, a truss core, or a similar core) that adds structural reinforcement to the tank panel16. The end caps76can include engineered gaskets55and/or tape disposed along the edge of the caps76between the caps76and the cap bracket74(and tank sheets) to form a fluid seal between the caps and76and the cap brackets74to prevent foam from leaking through the interfaces formed between the parts of the tank shell.

FIG.7Ashows a detail, cross-sectional view taken along line7-7inFIG.3. The top panel mates with the back panel14to form a thermally insulated joint60(e.g., a half-lap joint) where, in cross-section, one sheet of the pair of sheets of the one of the panels terminates at a surface (e.g., an interior surface) of a foam layer of the other one of the foam panels. For example, the lower sheet42has an edge71that ends at the interior surface73of the foam layer48of the back panel14. The edge71can directly contact the interior surface73or there can be an adhesive layer disposed between the two. Additionally, the internal sheet79of the back panel14can terminate at a surface49(e.g., an interior surface) of the lower sheet42of the top panel12. The interior surface49of the sheet42faces the interior volume ‘v’ of the refrigerated display case and spans the width of the top foam panel12.

In some implementations, the joint60can be a different type of joint such as a rabbet joint, a tongue and groove joint, a butt joint, a box joint, or a similar joint. However, the simplicity and reliability of the half-lap joint allows an operator or a machine to quickly assemble the two panels, while maintaining thermal insulation at the joint60. In other words, the joint60prevents any thermally conductive path (“short circuit”) from the inside of the case to the outside of the case10by any of the thermally conductive sheets42,45,77,79. The joint60forms the upper corner of the refrigerated display case.

FIG.7Bshows a joint60aof two panels15a,15barranged along a common plane. For example, the two panels15a,15bcan make the back wall of the refrigerated display. In the joint60a, the first foam panel15ahas a first flat foam edge and the second foam panel15bhas a second flat foam edge that corresponds with the first flat foam edge. As shown, the first foam panel15acan be inserted (e.g., as male and female connections) into the second foam panel15b. For example, the first flat foam edge of the first panel45aextends beyond a first edge or end of the first pair of liners45afirst distance. The second foam edge of the second panel15bis offset from a second edge of the second pair or liners45ba second distance equal to the first distance to form a female interface. When brought together, the panels15a,15bform a male-female connection with the first foam edge inserted into the second insulated panel and terminating at the second foam edge.

FIG.8illustrates an exploded view of a shell (e.g., the components surrounding the foam layer) of the tank panel16. The foam layer (not shown) of the tank16is sandwiched between the top sheet70and the bottom sheet80. The non-flat sheets70,80can be formed with different methods such as by folding the sheets, extruding the sheets, soldering multiple sheets together, etc. However, each sheet70,80is a one-piece sheet, which simplifies the manufacturing process of the tank panel16.

Referring also toFIGS.9and10, depending on manufacturing methodologies and the desired specifications of the tank foam panel, the tank foam panel can have top sheets70a,70bof different configurations. For example, as shown inFIG.9, the top sheet70acan have sharp corners or bends75a. Additionally, as shown inFIG.10, the top sheet70bcan have round corners or bends75b. The lower sheet80can similarly be square or round (not shown). The lower and upper sheets70,80form, in side view, a tank panel16with a non-flat cross-section.

Referring toFIG.8, one of the end caps76(e.g., the left end cap) can have a port84where liquid foam is injected during the manufacturing process. The end caps76can have an outer wall67surrounding the reinforcement core58. During manufacturing, the reinforcement core58of the end caps76allows foam to enter the volume defined by the outer wall67to reinforce the end caps76and bond the end caps76to the foam layer.

As further described in detail below with respect toFIGS.20-24, the sheets70,80, end caps76, and cap brackets74(e.g., a rearward cap bracket and a forward cap bracket) are assembled together to form an outer shell that is sealed to prevent the expanding foam from leaking through the shell during the manufacturing process of the tank16.

The end caps76define, in side view, a cross-section that corresponds with the non-flat cross-section of the sheets70,80. The caps76include two vertical surfaces57,59and a horizontal surface53extending between and connecting the two vertical surfaces57,59. There can be an angled surface extending between the horizontal surface53and one of the vertical surfaces59.

The end caps76together with the cap brackets74can form a frame or periphery that extending along all edges of the tank panel16and defines a volume, with the sheets70,80that contains the foam layer. The frame and the sheets70,80(e.g., the outer shell) are bonded to the foam layer during curing of the foam layer.

FIG.11illustrates a side view of the bottom or lower tank sheet80. The bottom sheet80has a first vertical surface81and a second vertical surface83opposing the first vertical surface81. The bottom sheet80has a first inwardly-projecting tab88that extends from the first vertical surface81(e.g., from an upper end of the sheet80). The tab88extends along the length (e.g., the entire length) of the sheet80. The tab88has, in side view, a hook shape. For example, the tab88has a horizontal portion91and an angled portion93extending from the horizontal portion91. Referring also toFIG.13, the tab88has a shape that corresponds with a first portion ‘A’ of a first cap bracket74(e.g., a rearward cap bracket). The portion ‘A’ of the cap bracket74has a horizontal and an angled portion similar to the horizontal and angled portion of the first inwardly-projecting tab88.

FIG.12illustrates a side view of the top or upper tank sheet70. The top sheet70has a first vertical surface72and a second vertical surface78facing away from the first vertical surface72. The top sheet70has a first outwardly-projecting tab86that extends from the first vertical surface72. Similar to the tab88of the bottom sheet80, the outwardly-projection tab86extends along the length (e.g., the entire length) of the sheet70and has, in side view, a hook shape. Referring also toFIG.13, the outwardly-projecting tab86has a shape that corresponds with a second portion ‘B’ of the first cap bracket74(the rearward cap bracket) opposite the first portion ‘A’. The portion ‘B’ of the cap bracket74has a horizontal and an angled portion similar to the horizontal and angled portion of the outwardly-projecting tab86.

As shown inFIG.11, the tank80has a second inwardly-projecting tab82that extends from the second vertical surface83. The second tab82is similar to the first tab88. For example, the second tab82extends along the length of the sheet80and has, in side view, a hook shape. Referring also toFIG.13, the second tab82has a shape that corresponds with a second portion ‘B’ of a second cap bracket74(e.g., a forward cap bracket) opposite the first portion ‘A’. Similar to portion ‘A’, portion ‘B’ of the cap bracket74has a horizontal and an angled portion similar to the horizontal and angled portion of the first inwardly-projecting tab88.

The cap bracket74has horizontal middle portion92that connects portion ‘A’ to portion ‘B’. The width of the middle portion92can depend, for example, on a thickness of the tank foam board. The cap bracket74also has vertical portions90that, together, embrace the ends of the bottom and top tank sheets70,80to help maintain the sheets or liners together.

Referring toFIGS.11and12, the bottom tank sheet80has a second inwardly-projecting tab82that, when assembled, faces a second outwardly-projecting tab89of the top tank sheet70, similar to the first tabs88,86of the tank sheets.

FIG.14illustrates a perspective view of an assembly line100for automatically manufacturing insulated foam panels. The assembly line100can include conveyors110(e.g., sheet and foam panel conveyors), one or more robotic arms106, one or more presses102,104, a foam nozzle (not shown), and a tool storage assembly (not shown) that may include a tool storage rack and a tool elevator.

The presses102has a lower panel tool112and an upper panel tool114. In some implementations, the lower and upper panel tools112,114used to make the back foam panel can be the same tools used to make the top foam panel. Additionally, the lower and upper panel tools112,114used to make the tank foam panel can be different than the panel tools112,114used to make the top and back foam panels.

The robotic arm106can be mounted on a linear track rail108. The robotic arm106can move along the linear track rail108to grab sheets from a conveyor110and position the sheets in the presses102,104. After the foam board is formed in one of the presses102,104, the arm106can move the foam boards to a conveyor110that takes the foam boards to another station (e.g., a trimming station). For example, components of the assembly line100can prepare the foam panels for assembly (e.g., by way of a half-lap joint) by cutting the foam panels to size and applying silicone sealant.

The robotic arm106can have an end of arm tool116(EAOT) that has multiple suction cups118(e.g., vacuum cups). The EAOT116can be moved toward a sheet laying on the conveyor110. Once the EAOT116is on top of the sheet, the suction cups118can engage the sheet to lift and move the sheet away from the conveyor110. The robotic arm106first places the lower sheet on a top surface of the lower panel tool112of the press102. The robotic arm106then places the upper sheet on top of a frame (e.g., a non-stick frame) of the lower panel tool112that is disposed on top of the lower sheet. With the lower and upper sheets in place, the press102lowers the upper panel tool114to press the sheets as the foam is injected and as the foam expands between the two sheets.

There are multiple embodiments of the EAOT116. For example, as shown inFIG.14, the EAOT116used to move flat sheets (e.g., sheets for the back foam panel and the top foam panel) can include a flat frame with vacuum cups residing along a common horizontal plane. The EAOT116can also hold different sizes of panels by selectively turning on or off groups of suction cups. An EAOT used to move sheets for the tank foam panel can have a similar flat frame but also include an adjustable clamp with suction cups that can hold opposite surfaces of a sheet with a U-shape cross-section. This clamp can be extendable and retractable to grip top and bottom sheets of different shapes and sizes.

FIG.15illustrates a perspective view of a press tool assembly200. The press tool assembly200includes a lower panel tool202and an upper panel tool204similar to the lower and upper panel tools112,114inFIG.14. The lower panel tool202and upper panel tool204are used to make flat foam panels (e.g., back and top foam panels).

The upper panel tool204has a top frame206with engagement features208(e.g., slots or fork-lift tubes). The press can engage the engagement features208to secure the upper panel tool204to the press. The upper panel tool204has a plate209that faces the lower panel tool202. The plate209directly contacts the top sheet during the manufacturing of the foam panels.

The lower panel tool202has a base210that is engaged by the press to secure the lower panel tool202to the press. The lower panel tool202also includes a top plate212and a middle frame214that resides between the base210and the top plate212. The top plate212faces the plate209of the upper panel tool204. The top plate212directly contacts the bottom sheet during the manufacturing of the foam panels. As further described in detail below with respect toFIGS.17and18, the lower panel tool202can also have actuators216(e.g., pneumatic guided cylinders) to move bars or rails of the lower panel tool202that form the non-stick frame.

FIG.16depicts a cross-sectional view of the press tool assembly200. The lower panel tool202has internal actuators217(e.g., stacked guided cylinders) that move the bars of the non-stick frame. The lower panel tool202also includes linear actuators223(e.g., dual ball screw linear actuators) that move side bars of the non-stick frame. The lower panel tool202also includes linear guides and rails213to help move the side bars. The top plate212of the lower panel tool204has a top surface220that supports the bottom sheet of the foam panel. The bars and side bars of the non-stick frame move along the top surface220of the lower panel tool204.

FIG.17illustrates a perspective view of the lower panel tool202andFIG.18shows a top view of the lower panel tool202. Referring toFIGS.17and18, the lower panel tool202has a configurable non-stick frame203that includes two longitudinal bars or rails224spaced from each other and two side bars222perpendicular with respect to and disposed between the longitudinal bars224. The configurable non-stick frame203allows the panel tool202to form flat foam panels of different lengths. For example, the two lateral, parallel bars224move along the length of the longitudinal, parallel bars224to form a rectangular volume ‘V’ (e.g., similar to a picture frame) defined between the four bars222,224. The four bars222,224together form the rectangular volume ‘V’ bordered by the bars222,224where the foam is to be deposited.FIGS.17and18show the lateral bars222in multiple positions along the top surface of the tool202to illustrate the different configurations of the non-stick frame203.

The longitudinal bars224can be moved by the side actuators216to press the bars224against the ends of the lateral bars222to prevent foam from leaking through the interface between the two bars222,224. The linear actuators223below the surface220of the tool202move the two side bars222to a desired location based on a length of the foam board to be made. The bars222,224can separate from each other (and in some cases from the top surface220) to allow the sheet to be placed on the top surface220of the bottom panel tool202. After the sheet is places on the top surface220, the bars222,224are moved to close the frame on top of the sheet.

The non-stick frame203on top of the sheet can create a pinch seal with the sheet metal to contain the foam. With the frame203closed, the foam nozzle deposits liquid foam on the bottom panel within the volume ‘V’. Each bar222,224of the frame203can have a non-stick coating that allows the rails to be quickly removed from the hardened foam once the foam panel is ready to be removed from the press. In some implementations, the bars222,224can have a cross-section that forms a half-lap joint cross section in the foam layer of the foam panel.

As shown inFIG.17, the top surface220of the lower panel tool202can have a vacuum surface226with vacuum channels228or holes to firmly grip the sheets and prevent the sheets from moving during the foaming process.

FIG.19depicts a top view of the upper panel tool204. The upper panel tool204can also have a vacuum surface236with vacuum channels238or holes that firmly suck and grip the sheets (e.g., the upper sheet) and prevents the sheets from moving during the foaming process. The upper panel tool204can have multiple vacuum surfaces236that can be selectably turned on and off depending on the size of the sheet.

During the manufacturing process, the foam nozzle deposits liquid resin or foam on the bottom sheet within the volume ‘V’ defined by the non-stick frame203. The EAOT places a top sheet on the frame203, overlaying the bottom sheet. The press lowers the upper panel tool204to press the top sheet against the frame203, thereby sandwiching the foam between the two sheets as the foam expands and hardens. With the foam hardened, the EAOT removes the foam panel from the press.

FIG.20illustrates a side view of a press tool assembly300according to a different implementation of the present disclosure. The press tool assembly300includes a lower panel tool302and an upper panel tool304. Similar to the lower and upper panel tools112,114inFIG.14, the lower and upper panel tools302,304are attached to respective lower and upper parts of a press. The lower panel tool302and upper panel tool304are used to make non-flat foam panels316(e.g., tank foam panels).

The upper panel tool304has a top frame306that is engaged by the press to secure the upper panel tool304to the press. The upper panel tool304has a plate309that has, in side view, a U-shape cross section. For example, the plate309includes a horizontal base311and two vertical walls313that can be moved by actuators317(e.g., linear actuators) to form a cross-section of the tank foam panel316and press the side walls313toward the foam panel. The plate309directly contacts the bottom tank sheet380of the tank foam panel during the manufacturing of the tank foam panels.

The lower panel tool302has a base310that is engaged by the press to secure the lower panel tool302to the press. The lower panel tool302also includes a top plate312and a middle frame314that resides between the base310and the top plate312. The top plate312faces the plate309of the upper panel tool304. The top plate312directly contacts the top tank sheet370during the manufacturing process of the tank foam panels.

The lower panel tool302also has lower actuators319to move the side caps376(see side caps76inFIG.8) of the tank foam panel316. The lower actuators319can be ball screw linear actuators with integrated linear guides to move and position the caps376at a desired location based on a length of the tank foam panel316. The lower panel tool302can also have a mechanical linkage321to move a drip insert323during the foaming process. The lower panel tool302can also have an edge support315that supports the longitudinal cap bracket of the tank316.

FIG.21illustrates a perspective view of the lower panel tool302andFIG.22illustrates a top view of the lower panel tool302. Referring toFIGS.21and22, the lower panel tool302has a vacuum surface336similar to the vacuum surface of the lower and upper panel tools inFIGS.17and19. The vacuum surface is located on a top surface of the top plate312of the lower panel tool302. The vacuum surface326has vacuum channels or holes that suck air to firmly grip the upper tank sheet and prevent the upper tank sheet from moving during the foaming process.

FIG.23is a perspective view of the upper panel tool304. The upper panel tool304has a mechanical linkage327attached to the actuator317. The mechanical linkage327moves a shaft325that pushes the walls313of the plate309of the upper panel tool304. The shaft325allows the actuators317to uniformly move the walls313of the plate309.

During the manufacturing process, a robotic arm (or a human operator) can move and assemble a ‘frame’ with the end brackets and longitudinal cap brackets on top of the upper sheet that is placed on top of the lower press tool302. One of the end brackets has an aperture configured to receive foam from the foam nozzle. Once the frame is in place, the EOAT places the lower tank sheet on top of the frame, and the press presses the two sheets against the frame while the nozzle injects foam through the aperture into the volume between the sheets and the frame. The press can insert a plug into the aperture to close the volume after depositing the liquid foam. The end brackets and longitudinal cap brackets (the ‘frame’) bond to the foam to be part of the final assembly of the foam tank panel.

The chemical product (e.g., the liquid resin or foam) used in this process includes chemical characteristics or properties that are suitable to be used with the described equipment. For example, the chemical product can include an R-Value of 1.5 or more (e.g., R-1.55) for the foam panel to have the required energy efficiency and insulation properties for different applications. The chemical product can also have a demold time of about 5 minutes, which allows the manufacturing assembly (e.g., the assembly line) to run at target capacity (e.g., 40 units per day-shift) with a minimum number of equipment components.

FIG.24is a flow chart of an example method400of assembling an insulated display case. The method400includes positioning a first insulated panel on a base of the insulated display case to form a first wall (405). The method also includes attaching a second insulated panel to the first insulated panel to form a second wall of the insulated display case. The second insulated panel has a second foam layer sandwiched between a second pair of thermally conductive sheets, wherein attaching the second insulated panel to the first insulated panel comprises forming a thermally insulated joint where, in cross-section, one sheet of the first pair of thermally conductive sheets terminates at a surface of the second foam layer (410).

FIG.25is a flow chart of an example method500of making an insulated foam panel. The method500includes placing a first liner on a top surface of a lower press tool (505). The method also includes positioning a frame at a top surface of the first liner, the frame bordering a volume defined between the top surface of the first liner and an interior surface of the frame (510). The method also includes depositing a liquid resin on the first liner within the volume (515). The method also includes pressing a second liner against the frame, the second liner overlaying the first liner while the liquid resin expands and solidifies into a foam between and bonded to the first liner and the second liner (520).

Although the following detailed description contains many specific details for purposes of illustration, it is understood that one of ordinary skill in the art will appreciate that many examples, variations and alterations to the following details are within the scope and spirit of the disclosure. Accordingly, the exemplary implementations described in the present disclosure and provided in the appended figures are set forth without any loss of generality, and without imposing limitations on the claimed implementations.

Although the present implementations have been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereupon without departing from the principle and scope of the disclosure. Accordingly, the scope of the present disclosure should be determined by the following claims and their appropriate legal equivalents.

As used herein, the terms “aligned,” “substantially aligned,” “parallel,” or “substantially parallel” refer to a relation between two elements (e.g., lines, axes, planes, surfaces, or components) as being oriented generally along the same direction within acceptable engineering, machining, drawing measurement, or part size tolerances such that the elements do not intersect or intersect at a minimal angle. For example, two surfaces can be considered aligned with each other if surfaces extend along the same general direction of a device or component. Similarly, the terms “vertical,” “substantially vertical,” “horizontal,” or “substantially horizontal” refer to a relation between two elements (e.g., lines, axes, planes, surfaces, or components) as being oriented generally at respective right angles within acceptable engineering, machining, drawing measurement, or part size tolerances such that the elements.