Patent Publication Number: US-11662134-B2

Title: Hot airflow management systems and methods for coolers

Description:
FIELD 
     Described embodiments relate to hot airflow management systems and methods for coolers. More particularly, the described embodiments relate to airflow management systems having discharge vents and turbulence reduction vents, and related methods. 
     SUMMARY 
     In some embodiments descried herein, a cooler includes a cabinet, a refrigeration unit, and an airflow management system. The cabinet has a door with a transparent section. The transparent section may be formed of glass, plastic, or other transparent materials. The refrigeration unit is coupled to the cabinet and includes an airflow inlet and an airflow outlet. A cross sectional area of the airflow inlet is greater than a cross sectional area of the airflow outlet. The airflow management system is in fluid communication with the airflow outlet. The airflow management system includes discharge vents and turbulence reduction vents. The discharge vents and the turbulence reduction vents are orthogonal. 
     The airflow management system is configured to redirect the flow of an air mass exiting the refrigeration unit through the airflow outlet. In some embodiments, the airflow management system redirects the flow of the air mass across a height of the transparent section. 
     The transparent section may comprise a substantial portion of a one side of the cooler. The height of the transparent section may greater than 95% the height of the cabinet. The height of the transparent section may also be greater than 85% the height of the cooler. The transparent section of the cooler may have a height that is between 6 ft and 6.5 ft. The reduced height of the refrigeration unit may be occupied by the cabinet to form a supplemental storage space. The supplemental storage space may be formed above the outlet of the refrigeration unit. 
     The refrigeration unit may include a condenser having coils. The coils may be located in the more narrow section of the refrigeration unit. The narrow section of the refrigeration unit may be the portion of the refrigeration unit that has the smaller cross section. The coils may form air mass channels that guide the air mass flowing through the refrigeration unit to the airflow outlet. According to some embodiments, the air mass channels are orthogonal to the door of the cooler. The width of the refrigeration unit (w) may also be constant through the cross sectional area of the outlet and the inlet. Thus, the change in cross sectional area from the inlet to the outlet is the result of a change in height of the refrigeration unit. 
     The cooler may have a cabinet height that is greater than 6 ft. The airflow management system may lessen the formation of condensation on the transparent portion of the cabinet when the interior of the cabinet has a temperature below 5° C. and the cooler is located in a high temperature and high humidity environment. A high temperature and high humidity environment may be described as one where the temperature exceeds 41° C. and the relative humidity exceeds 75%. 
     The airflow management system for a cooler may include a housing. The housing may be formed of a discharge panel and a side panel. The discharge panel and the side panel may be formed orthogonal to one another. Discharge vents may be formed in the discharge panel and turbulence reduction vents may be formed in the side panel. The airflow management system for a cooler may also include an arced plate interior the housing. 
     The housing may bend through 90°. In this way, an air mass meeting the arced plate may be redirected 90° relative to how the air mass met the arced plate. The discharge vents may be biased to direct the air mass nearer a surface of the transparent portion of the cooler. For example, the discharge vents may be biased towards a plane orthogonal to the discharge panel where the plane intersects a radius of the arced plate. 
     The arced plate may engage the side panel. For example, the arced plate may be fitted into a recess of the side panel such that the side panel supports the arced plate. The discharge vents may be formed of two or more rows of vents. For example, the discharge vents on the surface panel may include two rows and ten columns of vents. 
     According to some embodiments, a cooler may include a cabinet, a refrigeration unit, and an airflow management system. The cabinet may have a primary space and a secondary space. The secondary space may be an extension of the primary space. The refrigeration unit may have a first and a second portion. The height of the second portion of the refrigeration unit may be less than the height of the first portion of the refrigeration unit. The airflow management system may be fluidly coupled to the second portion. The cabinet may be disposed on the refrigeration unit such that the secondary space is disposed above the second portion. The cabinet and the refrigeration unit may form a rectangular profile. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG.  1    shows a cooler with an airflow management system according to an embodiment. 
         FIG.  2    shows a cross-sectional view of a cooler with an airflow management system taken along the line  2 - 2 ′ in  FIG.  1    according to an embodiment. 
         FIG.  3    shows a schematic cross-sectional view of a refrigeration system with an airflow management system taken along the line  2 - 2 ′ in  FIG.  1    according to an embodiment. 
         FIG.  4    shows an airflow management system according to an embodiment. 
         FIG.  5    shows a cross-sectional view of an airflow management system taken along the line  5 - 5 ′ in  FIG.  4    according to an embodiment. 
         FIGS.  6 A and  6 B  show flow vectors of an air mass up the front surface of a cooler according to an embodiment. 
         FIGS.  7 A and  7 B  show a thermal map of the front surface of a cooler according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the claims. Accordingly, references to “one embodiment”, “an embodiment”. “an exemplary embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. 
     Other embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. As used herein, ranges are inclusive of the end points, and “from,” “between,” “to,” “and,” as well as other associated language includes the end points of the ranges. As used herein, “approximately” or “about” may be taken to mean within 10% of the recited value, inclusive. 
     Merchants use coolers to keep products cold. Some coolers include a transparent section on the front of cooler. The transparent section may be made of glass or other transparent materials. The transparent section of the door allows consumers to see products in the cooler prior to making a selection. Clear visibility of the products in the cooler is important to producers, merchants, and customers. Clear visibility allows the product to be seen from a distance without opening the door of the cooler. This allows producers to not only to market the products, but also to convey greater brand recognition, or to promote upcoming or limited time products or promotions, even when the cooler is closed. Consumers require clear visibility of the products in the cooler so the customer can see what products are available and make purchases. Finally, merchants require clear visibility so consumers limit the amount of time the cooler door is open, improving the energy efficiency of the cooler. 
     In some environments, humidity forming on the transparent section obscures consumers&#39; views of products in the cooler. Humidity on the transparent section limits brand recognition, makes it harder for consumers to identify products in the cooler, and may require consumers to open the cooler to clearly view products, unnecessarily wasting energy. 
     Coolers operating in high humidity and high temperature environments are particularly susceptible to condensation forming on the glass. Condensation forms when the temperature of a surface is less than the dew point temperature of water vapor in air. The dew point temperature increases as relative humidity increases. In high temperature high humidity environments, such as, for example, those with temperatures greater than 38° C. and a relative humidity above 65%, the dew point temperature may be only one to five degrees Celsius below the ambient temperature. For example, when the temperature is 40° C. and the relative humidity is 75%, the dew point temperature is 35° C. When the temperature is 40° C. and the relative humidity is 90%, the dew point temperature is 38° C. And when the temperature is 38° C. and the relative humidity is 75%, the dew point temperature is 33° C. Therefore, in the temperatures and the relative humilities described above, condensation will form on the transparent section of the cooler when the exterior of the transparent section is 35° C., 38° C., and 33° C., respectively. 
     A cooler has a cold interior to keep products at a temperature that is desirable to consumers. Beverage coolers may have an interior temperature of about 1° C. to 7° C. The cool interior reduces the temperature of the transparent section of the cooler. If the exterior of the transparent section cools below the dew point temperature, condensation will form on the exterior of the cooler. Ensuring that the temperature of the transparent portion remains above the dew point of the water vapor reduces the formation of condensation. 
     An embodiment of a cooler having an airflow management system configured to reduce the formation of condensation on a transparent section of the cooler is described in detail with reference to the accompanying figures. 
     In some embodiments, for example as shown in  FIG.  1   , a cooler  100  includes a cabinet  102 . Cabinet  102  may store and display products. For example, cabinet  102  may store beverages other consumable products. Cabinet  102  may have a door  106  to access products inside cabinet  102 . Door  106  includes transparent portion  108 . Transparent portion  108  may be formed of glass or may be formed of other transparent materials such as, for example, Plexiglas, glass composite, or other suitable materials. According to some embodiments, cooler  100  also includes a refrigeration unit  200 . Refrigeration unit  200  may be configured to cool the interior space of cabinet  102 . Refrigeration unit  200  may be located under cabinet  102  and may support cabinet  102 , for example, as shown in  FIG.  1   . Refrigeration unit  200  may include an airflow management system  300 . Airflow management system  300  may be coupled to the front of refrigeration unit  200 . Airflow management system  300  may be configured to redirect the flow of air entering airflow management system  300 . Airflow management system  300  is fluidly coupled to refrigeration unit  200  and is located on the same side of cooler  100  as door  106  with transparent portion  108 . 
     Cooler  100  has a cooler height  104 . In some embodiments, cooler height  104  may be between 2 ft and 10 ft. In some embodiments, cooler height  104  is between 4 ft and 8 ft. Still in some embodiments, cooler height is between 6 ft and 7 ft. Door  106  has a door height  107  and transparent portion  108  has a transparent section height  110 . According to some embodiments, transparent section height  110  is greater than 85% of cooler height  104 . In some embodiments, transparent section height  110  is greater than 95% of cooler height  104 . Transparent section height  110  may be greater than 95% of door height  107 . 
       FIG.  2    shows a cross-sectional view of cooler  100  taken at the line  2 - 2 ′ according to some embodiments.  FIG.  2    shows cabinet  102  on refrigeration unit  200 . Refrigeration unit  200  has a condenser fan  216  located at an airflow inlet  208 . An airflow outlet  210 , opposite airflow inlet  208 , fluidly interfaces with airflow management system  300 .  FIG.  2    shows transparent portion  108  above airflow management system  300 . In one embodiment, airflow management system  300  is configured such that air mass  400  exits airflow management system  300  and flows along a substantially laminar trajectory  404 . Air mass  400  maintains a substantially laminar flow across the transparent section height  110  of cooler  100 . A laminar flow is a uniform flow and lacks lateral mixing. In a laminar flow, there are no or minimal cross-currents perpendicular to the direction of the flow. There are also no or few eddies or swirls in the flow. 
     Cabinet  102  may different spaces formed by the geometry of cabinet  102 . For example,  FIG.  2    shows primary space  115  and secondary space  116  of cabinet  102 .  FIG.  2    shows secondary space  116  formed adjacent to primary space  115 . According to some embodiments, secondary space  116  may not be adjacent to primary space  115 . As explained in greater detail with reference to  FIG.  3    below, refrigeration unit  200  has a second portion with a height less than the first portion height. The negative space created by the reduced height of refrigeration unit  200  forms the space for secondary space  116  of cabinet  102 . Secondary space  116  increases the useful space of cabinet  102  allowing merchants to make more products available to customers. This increases customer choice and increases the time between cooler  100  restocking. Making use of the space previously occupied by forward section  206  allows cooler  100  to maintain a rectangular shape allowing for easy integration into current merchant locations. 
       FIG.  3    is a detailed view of refrigeration unit  200  shown in  FIG.  2   . As shown in  FIG.  3   , refrigeration unit  200  has a rear section  202 , a forward section  206 , and an intermediate section  204 . Refrigeration unit  200  may include an airflow inlet  208  and an airflow outlet  210 . Rear section  202 , intermediate section  204 , and forward section  206  are fluidly connected such that a fluid may flow from an airflow inlet  208  formed at one side of rear section  202 , through rear section  202 , intermediate section  204 , forward section  206 , and out an airflow outlet  210  formed at one side of forward section  206 . Rear section  202  has a rear section height  212  that defines a surface area of airflow inlet  208 . Forward section  206  has a forward section height  214  that defines a surface area of airflow outlet  210 . As shown in  FIG.  3   , in one embodiment, rear section height  212  is larger than forward section height  214 , and the surface area of airflow inlet  208  is greater than the surface area of airflow outlet  210 . 
     In some embodiments, refrigeration unit  200  may include several sections. The sections may be fluidly coupled and may have different cross-sectional areas. For example, as shown in  FIG.  3   , refrigeration unit  200  includes three sections.  FIG.  3    shows rear section  202 , intermediate section  204 , and forward section  206 . Rear section  202 , intermediate section  204 , and forward section  206  house components for cooling cabinet  102 . As will be appreciated, refrigeration components (not shown) may include condensers, compressors, evaporators, evaporation values, or other suitable refrigeration components.  FIG.  3    shows a condenser fan  216  disposed near airflow inlet  208  of refrigeration unit  200 . Condenser fan  216  may be interior of rear section  202  exterior of rear section  202 . For example, condenser fan  216  may be coupled to refrigeration unit but remain outside of rear section  202 . 
     Condenser fan  216  brings an air mass  400  into refrigeration unit  200 . Air mass  400  passes through rear section  202 . Air mass  400  continues through intermediate section  204 . Intermediate section  204  reduces the volume of air mass  400  passes. As the volume of air mass  400  decreases, the speed of air mass  400  increases. Therefore, when air mass  400  enters forward section  206 , a velocity of air mass  400  is greater than the velocity of air mass  400  when it exits rear section  202 . This corresponding increase in air mass  400 &#39;s velocity allows air mass  400  to achieve a greater height when flowing up transparent portion  108 . That is, the increased velocity allows air mass  400  exiting airflow outlet  210  and flowing into airflow management system  300  to obtain sufficient speeds to create a laminar flow up transparent section height  110 . 
     As stated above, condenser fan  216  draws air mass  400  into refrigeration unit  200  from an environment. As air mass  400  travels through refrigeration unit  200 , air mass  400  passes over condensing coils  213 . Condensing coils  213  are arranged to form airflow channels  211 . Airflow channels  211  smooth the flow of air mass  400 , decreasing turbulence in the air flow, and increasing the laminar properties of the flow. Airflow channels  211  also direct the flow of air mass  400  so that the direction of the flow becomes substantially horizontal. As air mass  400  passes through airflow channels  211  and over condenser coils  213 , air mass  400  absorbs heat ejected from condenser coils  213 . Air mass  400 , now moving with an increased velocity and warmed by condenser coils  213  passes through airflow outlet  210 . 
       FIG.  4    shows a perspective view of airflow management system  300  according to an embodiment. Airflow management system  300  has a discharge panel  302  and side panel  304 . Discharge panel  302  and side panel  304  are orthogonal. Door  106  having transparent section  108  is shown as environment in  FIG.  4    for reference. When door  106  is closed on cabinet  102 , a bottom surface of door  106  is located at a door closed position  108 . Discharge panel  302  has discharge vents  306 . Discharge vents  306  direct air mass  400  up the front of cabinet  102 , creating airflow up the surface of door  106  and across transparent portion  108 . Turbulence reduction vents  307  are formed into side panels  304 . Turbulence reduction vents  307  allow portions of air mass  400  that do not have a substantially forward direction, i.e. in a direction parallel to airflow channels  211 , to bleed out of airflow management system  300 . 
       FIG.  4    shows turbulent air  402  exiting through turbulence reduction vents  307 . Portions of air mass  400  exiting discharge panel  302  through discharge vents  306  form a laminar flow across the outer surface of transparent portion  108 . Discharge vents  306  may have a variety of shapes or have a variety of configurations. For example, discharge vents  306  may have two, three, four, or more rows and several columns. Discharge vents  306  may be oval, as shown, triangular, round, square, or other shapes. Discharge vents  306  may have the same shapes and dimensions or may have different shapes and dimensions. 
       FIG.  5    shows a cross-sectional view of airflow management system  300  taken at the line  5 - 5 ′. Airflow management system  300  includes arced plate  312 . Arced plate  312  redirects air mass  400  exiting refrigeration unit  200 . Arced plate  312  changes the direction of the flow of air mass  400  from the substantially horizontal trajectory air mass  400  has when exiting airflow outlet  210  to a substantially vertical trajectory. Arced plate  312  has radius  314 . In some embodiments, arced plate  312  may have more than one radius  314  depending on the geometry of arced plate  312 . In some embodiments, arced plate  312  may transition through 90°. In some embodiments, arced plate may transition through more or less than 90°. Still, in some embodiments, arced plate may have a piecewise transition. 
     Air mass  400 &#39;s transition from horizontal flow to vertical flow introduces turbulence into air mass  400 . In contrast to the generally smooth, laminar flow of air mass  400  when exiting refrigeration unit  200  via airflow channels  211 , the turbulent portions of air mass  400  are characterized by chaotic local changes in pressure and flow velocity. The turbulent portions of air mass  400  interfere with the laminar portions of the flow and reduce the velocity of the flow. A reduce velocity of air mass  400  reduces the ability of air mass  400  to maintain a laminar flow across the height of transparent section height  110 . Laminar flows across the surface increase the rate of heat transfer so the more laminar and less turbulent the flow, the greater the heat transfer on the transparent section. 
     Turbulence reduction vents  307 , reduce the turbulence of air mass  400 , increasing the laminar flow properties of the flow. Turbulence reduction vents  307 , formed in side panels  304 , allow portions of air mass  400  that have a flow velocity that is not substantially vertical to exit airflow management system  300  through turbulence reduction vents  307 . The removal of turbulent portions of the flow of air mass  400 . Removed turbulent flow will not interact with the smooth flow inside of airflow management system  300  and will not reduce the overall laminar velocity of air mass  400  flow through the system. 
     According to some embodiments, airflow management system  300  includes additional airflow management components. For example,  FIG.  5    also shows flow deflectors  317 . Flow deflectors  317  may be formed at discharge vents  306 . Flow deflectors  317  may be formed at an angle  405  relative to intermediate vent portions  316 . Intermediate vent portions  316  are portions of discharge panel  302  that are between discharge vents  306 . Flow deflectors  317  may slightly redirect the flow of air mass  400  exiting airflow management system  300  through discharge vents  306 . The slight redirection of air mass  400  with flow deflectors  317  may be necessary to fine tune the flow of air mass  400  to ensure a more laminar flow across transparent portion height  110 . As shown in  FIG.  5   , flow deflectors  317  may be said to be biased in the direction of transparent portion  108 . As shown, flow diverters are biased towards a plane that intersects radius  314  and is orthogonal to discharge panel  302 . 
       FIGS.  6 A and  6 B  show flow diagrams of air mass  400  flowing across transparent portion  108 .  FIG.  6 A  shows cooler  100 A having a flow diverter  60 X). Flow diverter  600 , has an arced plate configured to redirect air mass  400  exiting refrigeration unit  200  up transparent portion  108  of cooler  100 A. While flow diverter  600  is similar in many respects to airflow management system  300  described above and includes discharge vents located on a discharge panel of flow diverter  600 , flow diverter  600  lacks turbulence reduction vents  307 . In contrast with cooler  100 A shown in  FIG.  6 A , cooler  100 B shown in  FIG.  6 B  has airflow management system  300  as described above. Specifically, cooler  100 B&#39;s airflow management system  300  includes turbulence reduction vents  307 . 
     The flow diagrams shown in  FIGS.  6 A and  6 B  show flow vectors of air mass  400  exiting cooler  100 A&#39;s flow diverter  600  and cooler  100 B&#39;s airflow management system  300 , respectively. The length of each flow vector corresponds to the length of the laminar flow across transparent portion  108 . That is, the length of each vector shows how far up transparent portion height  110  the flow of air mass  400  remains smooth, laminar, and generally remains in contact with transparent portion  108 . 
       FIG.  6 A  shows flow vectors of varying lengths and have a generally parabolic shape. The flow remains laminar across transparent portion  108  up to an extreme point  502 . On average, the flow remains laminar to an average point  506 . 
       FIG.  6 B  shows flow vectors of air mass  400  extending from airflow management system  300  up across transparent portion  108 .  FIG.  6 B  also shows flow vectors of air mass  510  extending from turbulence reduction vents  307 . As shown, flow vectors extending up across transparent portion  108  remain laminar to point  504 . In contrast to flow vectors shown in  FIG.  6 A , flow vectors in  FIG.  6 B  remain laminar across the entire face of cooler  100 B. Thus, air mass  400 , heated by refrigeration unit  200 , reaches the upper extremes of cooler  100 B. 
       FIGS.  7 A and  7 B  show heat diagrams of coolers  100 A and  100 B shown in  FIGS.  6 A and  6 B . The heat diagrams show temperatures of transparent portion  108 .  FIGS.  7 A and  7 B  show temperature zones  702 ,  704 ,  706 ,  708 , and  710 . Temperature zone  702  has a higher temperature than temperature zone  704 . Temperature zone  704  has a higher temperature than temperature zone  706 . Temperature zone  706  has a higher temperature than temperature zone  708 . Temperature zone  708  has a higher temperature than temperature zone  710 . Accordingly, temperature zone  702  is the highest temperature and temperature zone  710  is the lowest temperature. 
     As described above, as air mass  400  exits flow diverter  600  or airflow management system  300 , air mass  400  is warmed by refrigeration unit  200 . Air mass  400  transfers heat to across transparent portion  108 . The transferred heat increases the temperature of across transparent portion  108  and results in the varying temperature zones  702  to  710 . As the flow becomes less laminar and the temperature of air mass  400  decreases, the less heat transferred to transparent portion  108 . 
       FIGS.  7 A and  7 B  show temperature zone  710  on coolers  100 A and  100 B. As stated, temperature zone  710  is the lowest temperature on the surface of transparent portion  108 . The low temperature of temperature zone  710  makes temperature zone  710  the most susceptible to the formation of condensation. A comparison of  FIGS.  7 A and  7 B  compares the effectiveness of flow diverter  600 , which lacks turbulence reduction vents  307 , and airflow management system  300 , which includes turbulence reduction vents  307 . On average, the surface temperature the transparent portion  108  of cooler  100 B is higher than the surface temperature of the transparent portion  108  of cooler  100 A. Thus, the transparent portion  108  of cooler  100 B is less susceptible to the formation of condensation. 
     It is to be appreciated that the Detailed Description section, and not the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventor(s), and thus, are not intended to limit the present invention and claims in any way. 
     The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance. 
     The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents.