Patent Abstract:
An automatically adjustable swing seal for a rack-aisle freezing and chilling system extends, for example, from the top horizontal frame member of a racking structure and defines an intake opening along with side seals and a bottom seal. The swing seal is positioned at a height such that a product stack having a top edge positioned at any point along the face of the swing seat creates a seal between the intake opening and the stack via the swing seal, the side seals, and the bottom seal. Thus, stacks of varying heights may automatically be accommodated. Further, the bottom edge of the swing seal may be beveled, such that if a product stack is not evenly stacked a portion of the uneven stacking will not catch against the swing seal when the stack is pulled away from the opening.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 13/074,098 filed Mar. 29, 2011, the entire disclosure of which is hereby explicitly incorporated by reference herein. 
    
    
     BACKGROUND 
     1. Field of Invention 
     The present invention relates to a warehouse or structure that mass freezes and stores bulk foods and other products, and in particular to racking and chilling structures in the warehouse. 
     2. Description of Related Art 
     Two-stage freezer warehouses are known in which large pallets of items including meats, fruit, vegetables, prepared foods, and the like are frozen in blast rooms of a warehouse and then are moved to a storage part of the warehouse to be maintained at a frozen temperature until their removal. Such two-stage freezer warehouses require separate blast and storage rooms that encompass a relatively large amount of space. 
     U.S. patent application Ser. No. 12/877,392 entitled “Rack Aisle Freezing System for Palletized Product”, filed on Sep. 8, 2010, relates to an improved system for freezing food products. Shown in  FIG. 1  is a large warehouse  2  that is used to freeze and maintain perishable foods or like products. Large pallets of items, including meats, fruits, vegetables, prepared foods, and the like, are sent to warehouse  2  to be frozen employing a system whereby the palletized foods are frozen on storage racks. 
       FIG. 2  shows a top view of the interior of warehouse  2 , in which rows of palleted product are shown such that pallets  4  abut chambers  6 . As shown in  FIG. 3 , rows of racking  14  are positioned between aisles  10  and chambers  6 . Each chamber  6  is enclosed by a pair of end walls  15  and top panel  17 . Cold air produced in warehouse  2  is drawn through spacers  20  ( FIGS. 5 and 6 ) separating rows of cases  22  of product on pallets  4 , creating a palletized product stack which is disposed and sealed against the exterior of racking  14  ( FIG. 3 ) via forklifts  18 . 
     Chillers  8  ( FIG. 2 ) provided in the interior of warehouse  2  produce the cold air and maintain the temperature of ambient air within the warehouse space at a level below freezing. A plurality of racking structures  14  ( FIGS. 3 and 4 ) each define a plurality of adjacent air flow chambers  6  ( FIGS. 2 and 4 ) having air intake openings on opposite sides thereof and a plurality of air outlets having air moving devices, such as exhaust fans  12 , on top panels  17 , which causes freezing air to be drawn into chambers  6  through intake openings and to then exhaust into the warehouse space. The plurality of airflow chambers  6  are each defined by a pair of end walls  15  and top wall  17  having one or more air outlets and exhaust fans associated therewith ( FIG. 3 ). Pallets  4  on pallet guides are pressed against the intake openings such that a seal is formed between the pallets and the intake openings via side periphery seals, a bottom periphery seal, and atop periphery seal that is selectively adjustable via a vertically manually adjustable bracket to which the top periphery seal attaches. The seals together define each intake opening. Freezing air is drawn through air pathways  16  ( FIGS. 2, 4, and 5 ) within the palletized product in a direction towards chamber  6  to thereby quickly freeze the product. As shown in  FIG. 5 , spacers  20  may be placed between rows of cases  22  of product to provide air pathways  24  through which air flow can enter chamber  6 . 
     While the top periphery seal may be adjusted via the corresponding bracket, a manual adjustment is required before product stacks of varying heights my be disposed against the intake openings such that a seal is formed between the stacks and openings. What is desired is an improvement over the foregoing. 
     SUMMARY 
     The present disclosure provides an automatically adjustable swing seal that for the rack-aisle freezing and chilling system described above extends, for example, from the top horizontal frame member of a racking structure and defines an intake opening along with side seals and a bottom seal. The swing seal is positioned at a height such that a product stack having a top edge positioned at any point along the face of the swing seal creates a seal between the intake opening and the stack via the swing seal, the side seals, and the bottom seal. Thus, stacks of varying heights may automatically be accommodated. Further, the bottom edge of the swing seal may be beveled, such that if a product a stack is not evenly stacked, a portion of the uneven stacking will not catch against the swing seal when the stack is pulled away from the opening. 
     In one form thereof, the present disclosure provides an installation for chilling or freezing and cold storage of product stacks of palletized product, including a cold storage warehouse space, at least one chiller in the warehouse space that produces chilled or freezing air and maintains the temperature of ambient air in the warehouse space at chilled or below freezing, at least one air flow chamber including opposite walls, a plurality of air intake openings in at least one wall of the walls, and at least one air outlet having an associated air moving device for causing chilled or freezing air to be drawn into the chamber through the air intake openings and exhausted into the warehouse space through the air outlet, and swing seals disposed over respective air intake openings, each swing seal hingedly connected to the one wall via a hinge defining a horizontal axis about which the swing seal rotates. When stacks of product to be chilled or frozen are disposed in sealing engagement with the air intake openings against the swing seals, a top edge of each engaged product stack is disposed against a front panel of the swine seal to rotate the swing seal inward about said horizontal axis of the hinge such that the swing seal and peripheral walls defining the air intake opening create a seal between the engaged product stack and the air intake opening, and chilled or freezing air is drawn through the product stack to thereby quickly freeze the product. 
     In another form thereof, the present disclosure provides an installation for chilling or freezing and cold storage of palletized product, including a cold storage warehouse space, at least one chiller in the warehouse space that produces chilled or freezing air and maintains the temperature of ambient air in the warehouse space at chilled or below freezing, at least one air flow chamber including opposite walls, a plurality of air intake openings in at least one wall of the walls, and at least one air outlet having an associated air moving device for causing chilled or freezing air to be drawn into the chamber through the intake openings and exhausted into the warehouse space through the air outlet, and swing seals disposed over respective air intake openings, the swing seals extending forwardly of their respective air intake openings and being yieldably movable rearwardly toward the interior of the chamber. When product stacks to be frozen or chilled are disposed in sealing engagement with the air intake openings against the swing seals, the swing seals are pushed inwardly such that the swing seal and peripheral walls defining the air intake opening create a seal between the engaged product stack and the air intake opening, and chilled or freezing air is drawn through the product stack to thereby quickly freeze the product. 
     In yet another form thereof, the present disclosure provides an installation for chilling or freezing and cold storage of stacks of palletized product, the installation including a cold warehouse space cooled by a chiller and a chamber having a plurality of air intake openings in a wall thereof, a method for chilling or freezing the stacks of palletized product, including providing a swing seal over each of a plurality of intake openings, the seals extending forwardly of the respective openings and being yieldably movable rearwardly toward an interior of the chamber; moving a stack of palletized product against the periphery of one of the openings thereby contacting the respective swine seal and pushing the swing seal rearwardly such that the product stack is scaled against the periphery of the opening and the swing seal; and drawing chilled or freezing air through the product stack into the chamber and out of the chamber to thereby chill or freeze the product stack. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following descriptions of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a perspective view of a warehouse incorporating a freezing system in accordance with the present disclosure; 
         FIG. 2  is a diagrammatic top view of a freezer warehouse incorporating the system of the present disclosure; 
         FIG. 3  is a perspective view of the interior of the freezer warehouse; 
         FIG. 4  is a perspective end view of two rows of racking; 
         FIG. 5  is a diagrammatic perspective view showing the flow of chilling air through the palletized product; 
         FIG. 6  shows loading of the palletized product into the racks; 
         FIG. 7  shows the palletized product loaded into the racks and disposed against a swing seal of the racking; 
         FIG. 8  is an enlarged fragmentary view showing the palletized product disposed against the swing seal of  FIG. 7 ; 
         FIG. 9  is a perspective view of the racking structure with the palletized product disposed against the swing seal of  FIG. 7  as seen from the interior air chamber; 
         FIG. 10  shows loading of palletized product of an alternative height into the racks; 
         FIG. 11  shows the palletized product of  FIG. 10  loaded into the racks and disposed against a swing seal of the racking; 
         FIG. 12  is a fragmentary view showing the palletized product disposed against the swing seal of  FIG. 11 ; 
         FIG. 13  is a perspective view of the racking structure with the palletized product of  FIG. 10  disposed against the swing seal of  FIG. 11  as seen from the interior air chamber; 
         FIG. 14  shows palletized product of an another alternative height loaded into the racks and disposed against a swing seal of the racking, the swing seat disposed beneath a filler panel that seals a portion of an opening of the racking; 
         FIG. 15  is a perspective view of the racking structure with the palletized product of  FIG. 14  disposed against the swing seal of  FIG. 14  as seen from the interior air chamber; 
         FIG. 16  is a perspective view of a portion of the racking structure accommodating twenty-four pallets on each side thereof; and 
         FIG. 17  is an enlarged perspective view showing the support for the swing seal. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner. 
     DETAILED DESCRIPTION 
     An improved sealing system for an installation and method for chilling or freezing and cold storage of palletized product is disclosed herein. A chiller  8  provided in the interior of a cold storage warehouse  2  is used to maintain the temperature of ambient air within the space of the warehouse at a low level such as below freezing. A plurality of racking structures  14  each define a plurality of air flow chambers  6  each having walls with air intake openings on opposite sides thereof and an air outlet and fan  12  to enable freezing air to be drawn into the chamber through intake openings and exhausting into the warehouse space. 
     As further described below, palletized product stacks  52  on pallet guides  56  are pressed against the intake openings  54  such that a seal is formed between the palletized product stacks and the intake openings via side periphery seals, a bottom periphery seal, and an automatically adjustable top periphery swing seal, the seals together defining each intake opening  54 . Chilling or freezing air is drawn through air pathways within the palletized product in a direction towards the chamber to thereby quickly freeze the product, which may then advantageously be stored on the same rack on which it is frozen. Referring to  FIG. 6 , racking structure  14  includes wall  30 , which is one of a pair of walls  30  defining the exterior of racking structure  14 . End walls  15  are disposed between the pair of walls  30  on opposite ends of racking structure  14 . End walls  15 , walls  30 , and top panels  17  having exhaust fans  12  define interior chambers  6 . Referring to  FIG. 9 , chambers  6  may include posts  32  of racking structure  14  to provide stabilizing support to the structure. 
     Walls  30  are formed by interconnected vertical and horizontal steel frame members which may define a plurality of openings. Referring to  FIG. 6 , each wall  30  of racking structure  14  includes bottom horizontal frame member  34  forming a lower seal, vertical frame members  36  that form a pair of side periphery seals  36 , and top horizontal frame member  38 . Frame members  34 ,  36 , and  38  are preferably made of steel having flat faces but elastomeric material could be fastened to the front faces if desired. When product stack  52  is not disposed against wall  30 , as shown in  FIG. 6 , swing seals  40  (described below), frame members/seals  34  and bottom horizontal frame member  34  define a series of intake openings  54  spaced along wall  30  of racking structure  14 . 
     Support guides  56  assist to position product stacks  52  within separate bays along racking structure  14  and against individual bay intake openings  54  of wall  30 . The product stacks described herein may be loaded along the empty bays of first row R 1  and/or second row R 2 . Additional rows above the first and second rows for racking structure  14  are within the scope of this disclosure and may additionally include bays into which product stacks may be positioned and disposed against respective intake openings. Product stacks are positioned against empty bays having bay intake openings other either side of racking structure  14 , such that each intake opening of racking structure  14  is covered by a product stack. Filler panels (not shown) are utilized to cover any intake openings against which a product stack is not disposed to create and maintain a sufficient negative pressure environment within internal chamber  6 . 
     A product stack  52  may be disposed against an intake opening  54  of a wall  30  and pressed against a front panel  47  of a swing seal  40 , as described below, at a level corresponding to the height of the product stack, such that product stacks of varying heights may be utilized with the swing seal described herein without requiring a manual adjustment of the swing seal for such varying product stacks. As further described below, the product stack  52  presses against and rotates the swing seal  40  inwardly towards chamber  6  until the product stack abuts the frame members  34 ,  36  of the wall and a seal is created between the product stack and the intake opening. 
     Swing seal  40  is disposed below top horizontal frame member  38  of wall  30 . The swing seal may be made of a steel sheet, although other materials such as elastomeric materials may be used in desired. Swing seal  40  includes top panel  42 , a pair of side panels  44  and bottom panel  45 , which forms beveled bottom edge  46 . Top panel  42 , side panels  44 , and bottom panel  45  of swing seal  40  are disposed around the periphery of front panel  47 . Interior face  50  ( FIG. 9 ) of front panel  47  faces towards the direction of chamber  6  and exterior face  48  ( FIG. 6 ) of front panel  47  faces toward the product stack to be loaded. Further, side panels  44  define a thickness. When swing seal  40  is in an at rest position such that a product stack is not disposed against swing seal  40 , face  48  of front panel  47  protrudes forwardly from wall  30  at a distance corresponding to or less than the thickness of side panels  44 . 
     Referring to  FIG. 7 , when product stack  52  is disposed against intake opening  54  of wall  30 , swing seal  40  yieldably moves by pivoting rearwardly towards an interior of chamber  6  via rotating about a horizontal axis from a rest position to a seal position. Alternative designs of the swing seal may yieldably move rearwardly towards the interior of chamber  6  along a horizontal plane and, for example, against a spring biased three. In the seal position, as further described below, swing seal  40 , the pair of side periphery seals  36 , and bottom horizontal frame member  34  defining the lower seal create the seal between product stack  52  and intake opening  54 . 
     As mentioned above, the product stacks may vary in height, as shown by the different product stacks of  FIGS. 6 and 10 . For example, to cooperate with the swing seal of the present disclosure, the product stack may have a height ranging from a first height measured from floor  60  to just above bottom panel  45  of swing seal  40  to a second height measured from floor  60  to near the top portion of exterior face  48  of swing seal  40  that is at brackets  62  supporting swing seal  40 , as discussed further below. 
     The side panels  44  of swing seal  40  are attached to vertical frame members  36  of wall  30  via a pair of L-shaped brackets  62  such that swing seal  40  is rotatable about a horizontal axis, as described further below. Each bracket  62  includes legs  64  and  68 . Leg  64  is attached to an upper portion of frame member  36  via a fastener, such as a bolt, that extends through aperture  66  of leg  64 . Leg  68  is attached to an upper portion of side panel  44  of swing seal  40 . Side panels  44  each include a rod aperture for receipt of rod  72 . A hinge such as rod  72  extends through the pair of L-shaped brackets  52  and side panels  44  of swing seal  40  such that swing seal  40  can rotate about a horizontal pivot axis defined by rod  72 . Particularly, rod  72  extends through the rod apertures of swing seal  40  and apertures  70  of legs  68  of brackets  62  on either side of swing seal  40  and is retained in place by means of a pair of locking collars  73  fastened to rod  72  by set screws (not shown) as shown in  FIG. 17 . As rod  72  defines the horizontal axis, swing seal  40  may rotate about the horizontal axis inwards towards chamber  6 . 
     Referring to  FIG. 7 , as product stack  52  is placed or disposed against opening  54  as described above, a top corner of product stack  52  is pressed against face  48  of swing seal  40  ( FIG. 8 ) to move swing seal  40  from the rest position to the seal position. Referring to  FIG. 8 , swing seal  40  is rotated about a horizontal axis of rod  72  ( FIG. 9 ) until product stack  52  abuts side periphery seals  36  and lower seal  34  of wall  30 , at which point swing seal  40  is in the seal position. In the seal position, the area of exterior face  48  of swing seal  40  seals against the top edge  84  of product stack  52 . Exterior face  48  along with side panels  44  of swing seal  40  and seals  36  and  34  restrict the passage of air to chamber  6  outside of air being directed through spacers between cases on the product stack  52 , as described below. 
     Referring back to  FIG. 7 , chilled air is drawn into chamber  6  via product stack  52 . Product stack  52  includes cases  22  positioned on pallet  4 . Cases  22  are separated by spacers  20  such that, when product stack  52  is placed or disposed against wall  30 , air is drawn through spacers  20  ( FIG. 5 ), and/or through openings in the product boxes  22 , through intake opening  54  ( FIG. 6 ) into chamber  6  and exhausted through chamber  6  via exhaust openings such as fans  12  within top panel  17 . The air drawn through spacers  20  is chilled sub-freezing air circulated by chillers  8  ( FIG. 2 ). The chilled air is capable of freezing product of product stack  52  when drawn through spacers  20  and maintaining the product at the frozen temperature. 
       FIGS. 10-13  show the method described above of positioning a product stack against intake opening  54  with product stack  76  having an alternative height that is higher than product stack  52  shown in  FIGS. 6-9 . Referring to  FIG. 11 , as product stack  76  is placed or disposed against wall  30  as described above, a top edge  84  of product stack  76  presses against face  48  of swing seal  40 . Swing seal  40  is then rotated about a horizontal axis defined by rod  72  inwards towards chamber  6  to a sealed position, as described above ( FIG. 13 ). 
     Referring to  FIGS. 14-15 , a product stack may be positioned at a level below bottom panel  45  of swing seal  40 . In such situations, as shown in  FIG. 14 , filler panel  80  is attached below top horizontal frame member  38  of wall  30  such that it is disposed between top horizontal frame member  38  of wall  30  and top panel  42  of swing seal  40  to restrict any undesired passage of air into chamber  6 . Brackets  62  are attached to side periphery seals  36  below filler panel  80 , and swing seal  40  is attached to wall  30  via brackets  62 , in the manner described above. Product stack  82  of  FIGS. 14 and 15  is then at a height such that a top edge  84  of product stack  82  may interact with swing seal  40  to rotate swing seal  40  inwards towards chamber  6  ( FIG. 15 ), as described above, creating a seal between product stack  82  and the intake opening. 
     Further, in the described embodiments, bottom panel  45  of swing seal  40  forms an obtuse angle with front panel  47  to form beveled bottom edge  46 . The beveled edge  46  reduces the chance that the lower edge of the swing seal  40  catches onto a product stack when the stack is being pulled back from the intake opening, or being positioned against the intake opening. Beveled bottom edge  46  prevents a product stack from getting caught or hung up onto the bottom panel of the swing seal when the product stack is being pulled back from intake opening  54 . 
     Further, if product stack  76  has a height such that top edge  84  is at a height level with beveled bottom edge  46  of swing seal  40 , top edge  84  can seal against beveled bottom edge  46 . This allows for a greater sealable range based on product stack height than if the bottom edge were perpendicular to front panel  47 . 
     While this invention has been described as having exemplary designs, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

Technology Classification (CPC): 5