Refrigerator cooler and housing cabinet and an improved method of insertion of the refrigerator compressor unit

A refrigeration cooler is provided that includes a compartment to house a refrigeration unit. The unit is inserted into the compartment and positioned so as to avoid damaging the compartment or the seal on the top of the unit and to align the evaporation/air flow inlet and outlets located on the unit and in the compartment. This is accomplished by inserting and raising the unit within the compartment. In particular, both the unit and the compartment include incline surfaces that help raise the unit. The inclines raise the unit when the unit is slid into the compartment and the inclines on the back and bottom of the unit engage the bottom of the compartment, and the inclines at the back and bottom of the compartment engage the front of the unit. In this manner, the unit is raised so that the seal engages the upper surface of the compartment securing the unit.

FIELD OF INVENTION

The invention relates generally to refrigerator coolers and housing cabinets in addition to an improved method to install, secure and seal a compressor unit into a refrigerator cooler and housing cabinet.

BACKGROUND

In most commercial machines that include refrigeration units, such as industrial refrigerators, commercial refrigerators, coolers and vending machines, it is often necessary to install the refrigerator compressor into the refrigerator housing cabinet, such as during initial assembly or during maintenance. This can be a difficult task since the compressor is heavy and cumbersome. Moreover, in many instances the equipment can be damaged during the insertion and sealing process. This is particularly true for systems in which the compressor, condenser and evaporator are assembled as a single refrigeration unit to be installed in a refrigeration cabinet. In such systems, the top of the refrigerator unit and the interior of the housing cabinet may be harmed during insertion of the refrigeration unit into the cabinet. Specifically, portions of the refrigeration unit and the housing cabinet are often scratched, chipped or torn during insertion.

To correct some of these problems, prior art focused on a variety of solutions. Unfortunately, while some problems were addressed, others were not remedied. For example, in U.S. Pat. No. 4,539,737 to Kerpers et. al., the inventor taught a method for installing a compressor into a cooling device. In particular, U.S. Pat. No. 4,593,737 provided for a mounting plate onto which the user placed the compressor motor. The mounting plate is then installed into the housing cabinet. After connecting the compressor motor to the compressor unit with the proper electrical circuits, the compressor motor is installed and the mounting plate is removed. In this invention, however, the compressor motor is installed separately from, and attached independently to, the other portions of the cooling device. The entire compressor unit is not secured into the housing. As such, it is difficult to move or reposition the cooling device without first disconnecting the coolant conduits of the compressor motor.

Similarly, in U.S. Pat. No. 5,711,162 to Wolanin et al., the patent teaches a refrigerator compressor motor mounting pan arrangement formed from a metal plate. The compressor motor sits atop the plate. The plate also includes wheel wells so that the compressor motor can be transported along with the compressor and refrigerator unit. A series of brackets holds the compressor motor in place on the plate; however, as in the '737 Patent, the compressor and the motor are not completely secured within the housing, but rather, the housing utilizes the brackets to hold the compressor motor in place. Such an arrangement does not allow for the formation of a tight seal between the whole compressor unit and the refrigerator housing.

As noted above, the prior art failed to address problems related to “sealing” or securing the compressor into the cabinet. Specifically, based on the weight and cumbersome nature of the compressor unit, it is often difficult to connect the whole compressor to the cabinet to form a tight seal. In other, unrelated arts, the concept of “sealing” a cooling device within its housing is known; however, in these arts, the applications do not address the issues related to any damage to the cooling unit caused by such sealing mechanisms nor are the compressor units of the same size and heft. For example, U.S. Pat. No. 4,539,737 to Kerpers et al. (“'737 Patent) describes a method for installing a motor-compressor unit in a cooling device, specifically an air conditioner. In this patent, a type of mounting plate is attached to the housing cabinet. During the installation of an air conditioner motor compressor unit, the unit is pushed along flanges attached to the mounting plate until the unit is “sealed” in the cabinet. Again, this combination of features does not alleviate the issues related to damage caused to the unit and/or the housing cabinet. In actuality, the movement of the unit across the flanges and into the cabinet likely will scratch, tear or in some measure damage the cabinet. Furthermore, this patent, while not specifically limited to air conditioners, directs its embodiments to commercial air conditioners and, as such, does not describe how the system would work in the unrelated field of refrigeration units. This is a major concern considering the large discrepancy between the size and function of the appliances.

Accordingly, it is the object of the present invention to provide a refrigerator cooler and housing cabinet with an installed, secured and sealed refrigerator compressor unit.

It is a further object of the present invention to provide a refrigerator cooler and housing cabinet in which a refrigerator compressor unit is installed without damaging the compressor unit, cooler or the cabinet and, at the same time, forming a secure seal between the compressor unit and the cooler and cabinet.

It is a further object of the present invention to provide a refrigerator cooler and housing cabinet with an installed, secured and sealed refrigerator compressor unit in which the method of installing, securing and sealing the unit is safe and easy to perform.

It is still a further object of the present invention to provide a refrigerator cooler and housing cabinet with an installed, secured and sealed refrigerator compressor unit that is economical to manufacture.

It is still a further object of the invention to provide a refrigerator cooler and housing cabinet with an installed, secured and sealed refrigerator compressor unit that is durable and can be used by businesses as well as individuals.

Other objects and advantages will be apparent from the remaining portion of the specification.

SUMMARY OF THE INVENTION

The preferred embodiment of the apparatus of the present invention includes a refrigerator cooler with a housing cabinet that includes an opening for the insertion of the refrigeration unit. The refrigerator cooler may be a industrial refrigeration unit, commercial refrigerator, vending machine or any other machine with requirement for a refrigeration unit. The refrigeration unit has a back side, a front side, a lower side and an upper side. In the preferred embodiment, the refrigeration unit is made of metal. The upper surface of the unit includes an evaporator inlet opening and evaporator cool air exhaust opening. The perimeter of these openings are surrounded by a seal—preferably made of neoprene or a similar flexible material. Further, the lower side includes two incline surfaces that both extend downwardly towards the front side of the unit. Each inclined surface also includes a horizontal resting surface so that when the refrigeration unit is resting inside the cooler and compartment, the unit rests upon the horizontal resting surface. In the preferred embodiment, the unit also includes a flat metal plate or lip that extends downward from the front side of the unit. This lip includes openings for mating with bolts on the cooler to help secure the unit in place in the cooler.

The refrigeration unit housing compartment has a back side, a front side, a lower side and an upper side and an opening to receive the unit. In addition, the compartment has an upper support surface and a lower support surface, both preferably made of metal. The upper surface of the cabinet also includes an evaporator inlet opening and an evaporator cool air exhaust opening. These openings align with the corresponding openings on the unit so as to allow the air flow from the unit through the openings and into the cooler.

In addition, the lower support surface of the compartment also has two incline surfaces that extend upwardly towards the back surface of the compartment. These incline surfaces also include horizontal resting surfaces onto Which the unit will ultimately sit.

The compartment includes rails along the lower surface. The unit slides along the rails until the unit's incline surfaces engage the rails and simultaneously the lower incline surfaces of the compartment engage the unit so as to lift or raise the unit and raise it into position. In this position, the seal of the unit engages the upper portion of the compartment. In the preferred embodiment, the seal includes a magnetic core so that the seal will be secured against the upper portion of the metal compartment.

In addition, the lower surface of the compartment includes a bracket that runs across the front of the lower surface of the compartment. This bracket includes the aforementioned bolts that are secured into the openings in the lower lip of the unit. In this manner, the unit is secured inside the refrigeration compartment without damaging the unit or the compartment.

DETAILED DESCRIPTION

A refrigerator cooler1constructed in accordance with the present invention is seen generally in FIG.1. As seen inFIGS. 1 and 2, the refrigerator cooler1includes a refrigeration unit4and a refrigeration cabinet6.

As seen throughoutFIGS. 2-7, the refrigeration unit4has a backside8, a front side10, a lower side12and an upper side14. In the preferred embodiment of the invention, the refrigeration unit4is preferably made of metal. Further, the lower side12preferably includes a left side and right side incline surface16aand16bthat both extend downwardly towards the front side12. The right side incline surface16bis not shown well, but is a mirror-image of the left side incline surface16a. Each incline surface16aand16bincludes an adjacent horizontal resting surface18a,18bso that when the refrigeration unit or “unit”4is inside the cooler1, the unit4rests upon the horizontal resting surfaces18a,18bto support the unit4in the cooler1.

Also as seen inFIGS. 2-7, the lower surface12preferably includes a flat metal plate20with a downwardly extending lip22from the front side12of the unit4. In the preferred embodiment, the downward extending lip22includes openings46aand46b, but may include other similar mating devices, for engagement with the cooler1.

As demonstrated inFIGS. 3-7, the upper side14of the unit4preferably includes an evaporator inlet opening23and an evaporator cool air exhaust opening24. In addition, the vent26, as seen inFIG. 1, allows the flow of ambient air into the refrigeration unit4. Specifically, the interior (not shown) of refrigeration unit4is divided into a lower interior and upper interior section (not shown). In the preferred embodiment, the lower interior section includes the condenser (not shown). The backside8, adjacent to the lower section, includes three fans34a,34band34c, which can be seen in FIG.8. The three fans34a,34band34cventilate the lower interior section and cool the condenser by pulling the ambient air through the front side of the interior of the refrigeration unit4and through vent26, then across the condenser. The resultant heated air is then released out of the backside through the three fans34a,34band34cand out the back vent80of the compartment48.

The lower and upper interior sections are separated so that the condenser and the evaporator (not shown) of the unit4are separated. As seen inFIGS. 3-6, the evaporator is covered by a shock absorber40(made preferably of Styrofoam or some other similar shock absorbing material). In addition, unit4includes a temperature control gauge42to regulate the temperature of the air circulated through the cabinet6.

As seen inFIGS. 3-6and11a-c, the upper side of the refrigeration unit14includes a seal44secured around the perimeter of the evaporator inlet opening23and evaporator cool air exhaust opening24. Preferably the seal44is made of a flexible material such as neoprene and may include a magnate core. In addition, the seal44includes a dividing section45as seen inFIGS. 3-6. The dividing section45separates the evaporator inlet opening23and the evaporator cool air exhaust opening24so that the air flow is not intermixed.

As seen generally inFIGS. 1,2and more clearly inFIGS. 9 and 10, the cooler1includes the refrigeration unit housing compartment or compartment48. The compartment48houses the refrigeration unit4. The compartment48has a backside50, a front side52, a left side53, a lower side54, a right side55, an upper side56and an opening seen generally at58. The unit4is adapted to slide into opening58. In addition, the compartment48has an upper support surface60and a lower support surface61. The lower support surface61is preferably made of metal. The lower support surface61preferably has two incline surfaces62aand62b, as demonstrated inFIGS. 10 and 11a-c. The inclines62aand62boperate similarly to inclines16aand16bof the unit4. Incline surfaces62aand62binclude horizontal resting surfaces63aand63bonto which the unit4will ultimately sit during the installed position. Incline surface62aand62bare located at the backside50and extend in an upward manner, towards the backside50.

More particularly, the incline surfaces62aand62bare located along rails64aand64bwhich are located on the lower support surface61, as seen inFIGS. 9,10and11a-c. The rails64aand64bextend along the left and right sides53,55of the compartment48along the lower support surface61. Each rail64aand64bhas a back end66aand66band a front end68aand68b. The back ends66aand66binclude two stops67aand67bthat abut the unit4in the resting position as shown clearly inFIGS. 11a-11c.

As shown inFIG. 9, the compartment48also preferably includes a bracket70spanning across the front side52of the cabinet48. The bracket70preferably includes a horizontal surface72that forms part of the lower support surface61. The bracket70also includes a downwardly extending lip74, shown inFIGS. 11a-c, that preferably includes bolts76aand76b, shown inFIGS. 2 and 11c, on each side of the bracket70.FIG. 2clearly demonstrates the bolts76aand76bengaging the corresponding openings46aand46bin the downwardly extending lip22of the unit4.FIGS. 11a-11cshow the nuts77aand77b, (77bis not well shown, but is a mirror-image of77a) affixed to the bracket70, which receive the corresponding bolts76aand76b. In this preferred embodiment, the nuts77aand77breceive the respective bolts76aand76bto secure the refrigeration unit4within the compartment48.

A grill cover82, as seen inFIG. 1, and includes the vent26to allow the ambient airflow into the interior of the unit4to provide the aforementioned ventilation across interior of the unit4.

As seen clearly inFIGS. 11a-c, the unit4in the preferred embodiment has at least1handle84for pushing or pulling the unit4into or out of the compartment48. Specifically, as the unit4is pushed along site line11—11(as shown in11a,11band11c) it enters into the compartment48of the cooler1. Initially, the lower metal plate20of the unit4, comes into contact with the horizontal surface72of the bracket70, and the rails64aand64b. Further advancement of the unit4into the compartment48causes the side edges21aand21bof the metal plate20to slide along the rails64aand64b. Eventually the lower metal plate20engages the incline surfaces62a,62band the horizontal surface72engages the incline surfaces16a,16b. As the unit4advances yet further into the compartment48, the metal plate20and horizontal surface72slide upward along the incline surfaces62a,62band the inclines surfaces16a,16b, respectively, causing the unit4to move further into the compartment48, while simultaneously causing the unit4to move upward.

Up to this point, a space existed between the unit4and upper surface of the compartment60. However, as the unit4moves upward in the compartment48, the space decreases as seen clearly inFIG. 11band11c. Ultimately, when the unit4comes to a resting position on the horizontal surfaces18aand18bof unit4as well as the horizontal surfaces63aand63bof the compartment48, the unit4will abut against the stops67aand67b. In addition, the seal44is now pressed tightly against the upper surface of the compartment60. This secures the unit4in place within the compartment48. In addition, as previously noted, the seal44may have a magnetic core and, as such, the seal44is additionally secured, magnetically, with the upper support surface of the compartment60. Once in this position, the bolts74aand74bmay be inserted into the openings46a,46band secured in place via nuts77aand77b, so that the unit4can be securely fastened into the compartment48.

FIG. 12shows openings86aand86bof compartment48that are aligned with the evaporator inlet opening23and outlet24of the unit4, when the unit4is in the installed position ofFIG. 11c. The openings86aand86bare found in the upper surface56of the compartment48. The openings86aand86ballow the flow of air from the corresponding evaporator inlet opening23and evaporator cool air exhaust opening24to circulate air in the refrigeration cooler cabinet6. Specifically, the airflow circulates through a baffling system88aand88bto the refrigeration cooler cabinet6. The details of the baffling system88a,88bare not shown. However, one skilled in the art will appreciate the requirements of the baffling system. In this manner, the refrigeration cooler cabinet6is cooled. As seen clearly inFIG. 1, the openings86aand86bare covered (preferably) by a hard plastic sheet90so that food items in the refrigeration cooler cabinet6do not slip through the openings86aand86band into the unit4. The refrigeration cooler cabinet6can maintain food items of other products in a variety of methods including the shelving system as seen generally at92as shown inFIG. 1or in a vending machine-type format.