Patent Publication Number: US-10314411-B2

Title: Refrigerated merchandiser with airflow support system

Description:
BACKGROUND 
     The present application relates to refrigerated merchandisers and, more particularly, to conditioning product display areas of refrigerated merchandisers. 
     In conventional practice, supermarkets and convenience stores are equipped with refrigerated merchandisers, which may be open or provided with doors, for presenting fresh food or beverages to customers while maintaining the fresh food and beverages in a refrigerated environment. Typically, refrigerated air is provided to a product display area of the merchandiser by passing airflow over the heat exchange surface of an evaporator. A refrigerant passes through the evaporator and heat is absorbed from the air passing through the evaporator. As a result, the temperature of the air passing through the evaporator is lowered for introduction into the product display area of the merchandiser. 
     SUMMARY 
     According to an exemplary embodiment, a refrigerated merchandiser includes a case having a lower wall, an upper wall, a rear wall, and a rear panel spaced from the rear wall. The lower wall, the upper wall, and the rear panel at least partially define a product support area. The case further defines a first air passageway in fluid communication with the product support area. The first air passageway has a vertical portion disposed between the rear wall and the rear panel. A fan is positioned in the first air passageway and is configured to generate an airflow through the first air passageway and into the product support area. An evaporator is disposed in the first air passageway and configured to condition the airflow. A duct is disposed between the rear wall and the rear panel. The rear panel and the duct cooperatively defining a second air passageway. The duct is positioned to overhang a portion of the evaporator to receive air directly from the evaporator. The first air passageway is configured to direct conditioned air to the product support area. The rear panel includes apertures configured to provide fluid communication between the second air passageway and the product support area. The second air passageway is configured to direct conditioned air to the product support area separate from the first air passageway. 
     According to another exemplary embodiment, a refrigerated merchandiser includes a case having a lower wall, an upper wall, a rear wall, and a rear panel spaced from the rear wall. The lower wall, the upper wall, and the rear panel at least partially defining a product support area. The case further defines a first air passageway in fluid communication with the product support area. The first air passageway has a vertical portion disposed between the rear wall and the rear panel. A fan is positioned in the first air passageway and configured to generate an airflow through the first air passageway and into the product support area. An evaporator is disposed in the first air passageway and configured to condition the airflow. The rear panel includes an aperture defined by an extruded projection extending into the product support area. 
     According to another exemplary embodiment, a refrigerated merchandiser includes a case having a canopy, a base, and a rear wall. A product support area at least partially defined by the lower wall and the upper wall. An upper flue at least partially defined by the canopy, a lower flue at least partially defined by the base, and a rear flue at least partially defined by the rear wall. The upper flue, lower flue, and rear flue defining an air passageway. An outlet defined by the canopy is configured to provide fluid communication between the air passageway and the product support area forming an air curtain. A fan is positioned in the first air passageway and configured to generate an airflow through the first air passageway and into the product support area. An evaporator is disposed in the first air passageway and configured to condition the airflow. The case includes a rear panel disposed between the rear flue and the product support area. The rear panel has an aperture defined by a nozzle configured to direct air generally horizontally toward the air curtain. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The aspects and features of various exemplary embodiments will be more apparent from the description of those exemplary embodiments taken with reference to the accompanying drawings. 
         FIG. 1  is a front view of an exemplary refrigerated merchandiser including shelves and embodying the invention. 
         FIG. 2  is a section view of the merchandiser of  FIG. 1  taken along line  2 - 2  and illustrating a rear panel defining a product support area, as well as an airflow passageway and an air duct disposed behind the rear panel. 
         FIG. 3  is a rear perspective view of the rear panel and duct. 
         FIG. 4  is a front, exploded perspective view of the rear panel and the duct of  FIG. 3 . 
         FIG. 5  is a view of the rear panel and the duct of  FIG. 3 . 
         FIG. 6  is an enlarged view of detail A of  FIG. 2 . 
         FIG. 7  is an enlarged view of detail B of  FIG. 2 . 
         FIG. 8  is a bottom perspective view of one of the shelves of the merchandiser illustrated in  FIGS. 1 and 2 . 
         FIG. 9  is an exploded view of the shelf of  FIG. 8 . 
         FIG. 10  is a perspective section view of a portion of the merchandiser and illustrating the rear panel, the duct, and shelves of the merchandiser, as well as airflow into the product support area. 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
       FIGS. 1 and 2  illustrate an exemplary embodiment of a refrigerated merchandiser  10  that may be configured as a low temperature merchandiser or a medium temperature merchandiser. The merchandiser  10  can include one or more interconnected case sections that may have respective refrigeration components (e.g., evaporator, expansion valve, etc.) of a refrigeration system, or that may share one or more refrigeration components of the refrigeration system. 
     With reference to  FIGS. 1 and 2 , the merchandiser  10  includes a case that has a canopy  12 , a rear wall  14 , and a base  16 . The canopy  12  and the base  16  are spaced from one another to at least partially define a case opening. The canopy  12  includes an upper wall  18  facing the interior of the merchandiser  10  and the base  16  includes a lower wall  20  facing the interior of the merchandiser  10  opposite the upper wall  18 . 
     The merchandiser  10  also includes a rear panel  22  that is is positioned interior of the rear wall  14 . The rear panel  22  includes one or more apertures  23  or one or more sets of apertures  23  that provide fluid communication through the rear panel  22 . As shown in  FIGS. 1 and 4 , the rear panel  22  includes four sets of apertures  23 , although fewer or additional sets of apertures can be provided. Each set of apertures  23  includes a first row of apertures  23 A and a second row of apertures  23 B that are spaced in close, vertical proximity to each other. As illustrated in  FIG. 1 , the first row of apertures  23  is offset from the second row of apertures  23  in the horizontal direction, although the apertures  23  in each set can be vertically aligned (i.e. not offset in the horizontal direction). 
     The area bounded by the lower wall  20 , the upper wall  18 , and the rear panel  22  at least partially defines a product support area  24 . One or more shelves  26  extend from the rear panel  22  into the product support area  24  to display and support products. 
     The merchandiser  10  has a lower flue  28  that is at least partially defined by the base  16  and that is in fluid communication with a rear flue  30  at least partially defined by the rear wall  14 . The lower flue  28  is positioned below the lower wall  20  and is in fluid communication with the product support area adjacent the case opening such that air can be drawn into the flue  28  from the product support area  24 . The rear flue  30  is in fluid communication with an upper flue  32  at least partially defined by the canopy  12 . The rear flue  30  is oriented to redirect the airflow from the lower flue  28  into a substantially vertical airflow through the merchandiser  10 . 
     The upper flue  32  is positioned above the upper wall  18  and is oriented to redirect the vertical airflow in the rear flue  30  into a horizontal airflow that is directed toward an outlet  33  in the canopy  12 . The outlet can include one or more openings, and a louver (not shown) can be positioned over the outlet to define an airflow profile for air that is directed generally downward across or in front of the product support area  24  to generate a front air curtain  34 . 
     The merchandiser  10  also includes a refrigeration system (not entirely shown) that conditions the airflow directed into the product support area  24  to cool product located in the product support area  24 . As shown in  FIG. 2 , the refrigeration system includes one or more fans  36  (one shown) and an evaporator  38 . As illustrated, the fan  36  is positioned in the lower flue  28  and is configured to generate an airflow. The evaporator  38  shown in  FIG. 2  is positioned in the rear flue  30  downstream of the fan  36 . As will be appreciated, the evaporator  38  may be positioned upstream of the fan  36  such that the fan  36  draws air through the evaporator  38 . Other components associated with the refrigeration system, including sensors and controllers can be provided with the merchandiser  10  or remote from the merchandiser  10  to monitor and control the refrigeration system. As will be appreciated by one of ordinary skill in the art, the types of and locations for refrigeration system components can be varied. 
     As shown in  FIGS. 2 and 3-5 , the merchandiser  10  includes a duct  40  that is disposed n the rear flue and that has an outer flange  44  coupled to the rear panel  22 . The flange  44  extends along the sides and the top of the rear panel  22 , either continuously or discretely. With reference to  FIG. 4 , the illustrated duct  40  and the rear panel  22  are formed as separate pieces that are attached to each other (e.g., via fasteners or other attachment features such as welding, brazing, adhesion, etc.). In some embodiments, the rear panel  22  and duct  40  can be formed together as a unitary structure or each component can be formed from multiple pieces and joined together or otherwise coupled. 
     The lower flue  28 , the void in the rear flue  30  between the rear wall  14  and the duct  40 , and the upper flue  32  cooperatively define a first air passageway  35 . As shown in  FIGS. 2 and 3-5 , the lower flue  28  and the duct  40  cooperatively define a second air passageway  42 . Air is configured to flow through the evaporator  38  into the second air passageway  42  substantially parallel to the airflow in the first air passageway  35  within the rear flue  30 . As shown in  FIG. 6 , the duct  40  overhangs at least a portion of the evaporator  38 . The duct  40  can be positioned adjacent or in contact with the evaporator  38  so that it receives air substantially directly from the evaporator  38 . For example, air leaving the portion of the evaporator  38  that is directly beneath the duct  40  may only flow into the second air passageway  42  without entering the remainder of the first air passageway  35  upstream of the inlet to the duct  40 . As a result, air leaving the evaporator  38  can be divided upstream of the evaporator into a first portion that flows through the first air passageway  35  and a second portion that flows through the second air passageway  42 . 
     With reference to  FIGS. 5 and 10 , the portion of the second air passageway  42  defined by the duct  40  tapers from a lower portion to an upper portion of the panel  22 . Stated another way, the second air passageway  42  has, in cross section, a throat width dimension that is greater adjacent the evaporator coil  38  than adjacent the canopy  12  such that the volume of the second air passageway  42  is reduced in a vertical direction (upward as illustrated in  FIG. 2 ). The tapered configuration of the second air passageway  42  maintains a steady airflow through the second air passageway  42 , even as air leaves through the apertures  23 . The tapered shape defined by the duct  40  provides a substantially constant airflow rate from the bottom to the top of the second air passageway  42  within the duct  40 . It will be appreciated that the length of the duct  40 , the quantity of apertures  23 , or the arrangement of the apertures  23  (e.g., spacing, size, pattern, or configuration), or any combination of these features can differ depending on desired fluid and thermal characteristics of the merchandiser  10 . 
     With reference to  FIG. 7 , the apertures  23  are defined by nozzles  46  that project or extend into the product support area  24  to direct air from the second air passageway  42  into the product support area  24 . The term ‘nozzle’, as described and claimed, refers to structure that directs or diverts airflow apart from a plain opening or hole formed in a panel. The exemplary nozzles  46  have a substantially cylindrical configuration with a fillet or rounded transition  47  between a planar surface of the rear panel  22  and the end of the nozzle  46 . The nozzles  46  can be formed in the rear panel  22  via an extrusion process or another process that produces nozzles  46  extending from the rear panel  22  into the product support area  24 . In some embodiments, the nozzles  46  and the rear panel  22  may be formed separately and joined or connected together. The size, shape, configuration, and orientation of the nozzles  46  can also be altered from what is illustrated. 
     Unlike typical openings that can cause air to exit in a non-uniform manner, creating turbulence, the nozzles  46  control the airflow through the rear panel  22 . The illustrated nozzles  46  redirect and straighten at least a portion of the airflow from the second air passageway  42  as the air passes through the rear panel  22 . In some embodiments, the nozzles  46  reduce or eliminate turbulence and provide substantially uniform, horizontal airflow through the nozzle  46  and into the product support area  14 . The airflow from the nozzles  46  can help support the front air curtain  34 . For example. The airflow through the nozzles  46  can provide air to the front of the case that supports the thermal barrier between the case and the ambient environment, without breaking or disrupting the front air curtain  34 . 
     With reference to  FIGS. 1, 2, and 10 , each set of apertures  23  is positioned below a respective shelf  26 .  FIGS. 8 and 9  show an exemplary shelf  26  that has an upper surface  50  for supporting a product and a pair of side brackets  52 . The side brackets  52  include one or more arms  54  that extend into slots formed in the rear panel  22  to releasably connect the shelf  26  to the case. One or more sets of apertures  23  can be positioned in or bounded by an area at least partially defined by the side brackets  52 . For example, the illustrated apertures  23  are horizontally positioned between the side brackets  52  and vertically positioned between a lower edge of the side brackets  52  and the upper surface  50  of the shelf  12 . As shown in  FIG. 9 , the shelf  26  can include one or more support brackets  56  formed integrally with, or connected to, an underside of the shelf  26 . 
     As illustrated in  FIGS. 8 and 9 , a cover plate  58  is connected to a lower side of the shelf  26 . The cover plate  58  has a smooth, planar bottom surface (as viewed in  FIG. 9 ), a front lip, and a rear lip. Fasteners (e.g., screws) can be used to attach the cover plate  58  to the shelf  12 , or the cover plate  58  can be adhered, welded, fused, or attached to the shelf  12  in other ways (e.g., snap-fit, friction-fit, etc.). The cover plate  58  overlays the lower side of the shelf  26  and encloses the support brackets  56  to provide a smooth surface along which the airflow passes toward the front of the product support area  24  after discharge through the apertures  23 . 
     The foregoing detailed description of the certain exemplary embodiments has been provided for the purpose of explaining the general principles and practical application, thereby enabling others skilled in the art to understand the disclosure for various embodiments and with various modifications as are suited to the particular use contemplated. This description is not necessarily intended to be exhaustive or to limit the disclosure to the exemplary embodiments disclosed. For example, although the invention is described and illustrated herein with reference to an open-front, vertically-oriented merchandiser, other types of merchandisers or display cases can utilize aspects of the invention described, illustrated, and recited herein. Also, any of the embodiments and/or elements disclosed herein may be combined with one another to form various additional embodiments not specifically disclosed. Accordingly, additional embodiments are possible and are intended to be encompassed within this specification and the scope of the appended claims. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way. 
     As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” and other orientational descriptors are intended to facilitate the description of the exemplary embodiments of the present disclosure, and are not intended to limit the structure of the exemplary embodiments of the present disclosure to any particular position or orientation. Terms of degree, such as “substantially” or “approximately” are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments.