COOLING SYSTEM

Abstract

A system for cooling a product includes an enclosed environment having an outlet, an inlet, and a temperature in a first temperature range. An antechamber is at least partially surrounding the inlet of the enclosed environment and has a temperature in a second temperature range. A conveyor system includes a conveyor path extending between the inlet and the outlet of the enclosed environment and provides a spiral travel path. The temperature range of the enclosed environment is configured to cool the product before the product exits through the outlet of the enclosed environment.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The priority benefit of U.S. Provisional Appl. No. 63/120,057, filed Dec. 1, 2020, is hereby claimed and the entire contents are incorporated herein by reference.

FIELD OF DISCLOSURE

The present disclosure generally relates to a cooling environment, and more particularly, to a system for cooling or freezing products in a cooling environment.

BACKGROUND

Many products are sold to customers in a frozen condition or delivered with frozen gel packs. The process of freezing a product varies in complexity and cost, depending on the properties and quantity of product being frozen and equipment used for freezing the product. Typically, after a product such as, for example, pizza dough, is frozen, the frozen dough is stored in a freezer until the dough is shipped in bulk to a different location, via refrigerated freight or truck, where the frozen dough is sold or distributed to a customer. If a single frozen dough product is shipped to a customer, the shipment typically includes a frozen gel pack to keep that frozen product at low temperatures during transport.

As the need for delivering refrigerated and frozen products directly to customers increases, so too does the need for manufacturing gel packs that accompany those deliveries. Gel packs are often used for shipping non-frozen and frozen products because they have long freeze times and are safe for shipment alongside produce. Freezing gel packs in bulk (like freezing pizza dough in the example above), however, may be time consuming and costly. For example, freezing gel packs in bulk may take days and even up to weeks to completely freeze. Additionally, gel packs are bulky and heavy when frozen en masse, occupying more space for storage and shipping, which increases overall costs for providing frozen gel packs. Furthermore, shipping frozen gel packs requires a heightened level of care because an outer packaging of a gel pack may be ruptured if not handled carefully, thereby spilling the contents and damaging the product and potentially other products in its vicinity when defrosted.

SUMMARY

In accordance with a first exemplary aspect of the present disclosure, a system for cooling a product may include an enclosed environment having an outlet, an inlet, and a temperature in a first temperature range. An antechamber may at least partially surround the inlet of the enclosed environment. The antechamber may have a temperature in a second temperature range. A conveyor system may include a conveyor path extending between the inlet and the outlet of the enclosed environment and may provide a spiral travel path. The temperature range of the enclosed environment may be configured to cool the product before the product exits through the outlet of the enclosed environment.

In accordance with a second exemplary aspect of the present disclosure, a system for cooling a product may include an enclosed environment having an inlet and an outlet. A conveyor system may include a conveyor path extending between the inlet and the outlet of the enclosed environment. The conveyor path may include an inlet portion, an outlet portion, and a spiral portion connecting the inlet and outlet portions. The inlet portion may be adjacent to the inlet of the enclosed environment and the outlet portion may be adjacent to the outlet of the enclosed environment. The spiral portion may define an ascending spiral travel path to transport a product from the inlet to the outlet of the enclosed environment.

In accordance with a third exemplary aspect of the present disclosure, a method of cooling a product may include placing a product in an antechamber connected to an inlet of an enclosed environment. The enclosed environment may have the inlet, an outlet, and a conveyor disposed in the enclosed environment and extending from the inlet to the outlet. The method may include transporting the product from the antechamber into the enclosed environment, and cooling the product as the product travels on a spiral travel path between the inlet and the outlet. Further, the method may include delivering a cooled product through the outlet of the enclosed environment.

In further accordance with any one or more of the foregoing first, second, and third exemplary aspects, an accessible cooling environment may include one or more of the following forms.

In one preferred form, the conveyor path may include an inlet portion disposed at a first height.

In one preferred form, the conveyor path may include an outlet portion disposed at a second height greater than the first height.

In another preferred form, the conveyor path may include an inlet portion at least partially disposed in the antechamber.

In another preferred form, the conveyor path may extend through the inlet of the enclosed environment.

In another preferred form, the conveyor path may move in an ascending spiral.

In another preferred form, the antechamber may include a pneumatic door controllable to open and close to receive a product before the product enters the enclosed environment.

In another preferred form, a refrigeration control system may control the temperature in the first temperature range and the temperature in the second temperature range.

In another preferred form, a conveyor control system may control the speed of the conveyor path.

In another preferred form, an antechamber may be coupled to an exterior wall of the enclosed environment.

In another preferred form, the antechamber may at least partially surround the inlet of the enclosed environment.

In another preferred form, the inlet portion of the conveyor path may be at least partially disposed in the antechamber.

In another preferred form, the inlet portion may extend through the inlet of the enclosed environment.

In another preferred form, the enclosed environment may have a temperature in a first temperature range.

In another preferred form, the antechamber may have a temperature in a second temperature range.

In another preferred form, the method may include setting, via a control system, a first temperature in a first temperature range of the enclosed environment.

In another preferred form, the method may include setting a second temperature in a second temperature range of the antechamber.

In another preferred form, cooling the product may include transporting the product between the inlet and the outlet in an ascending spiral travel path.

In another preferred form, placing a product in an antechamber may include automatically opening a door to the antechamber to receive the product and immediately closing the door after receiving the product.

In another preferred form, transporting the product may include conveying the product via a conveyor belt from the antechamber to the enclosed environment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial, perspective view of a first exemplary cooling system assembled in accordance with the teachings of the present disclosure, showing some of the interior components of the system;

FIG. 2 is a partial, front view of the cooling system of FIG. 1;

FIG. 3 is a partial, top view of the cooling system of FIG. 1;

FIG. 4 is a partial, front perspective view of a second exemplary cooling system assembled in accordance with the teachings of the present disclosure, showing some of the interior components of the system;

FIG. 5 is a partial, magnified view of a first station of the cooling system of FIG. 4;

FIG. 6 is a partial, magnified view of a second station of the cooling system of FIG. 4;

FIG. 7 is a partial, back perspective view of a third station of the cooling system of FIG. 4;

FIG. 8 is a partial, magnified view of the third station of the cooling system of FIG. 4;

FIG. 9 is a partial, front view of the cooling system of FIG. 4, showing a plurality of products at various stages of cooling in the cooling system; and

FIG. 10 is a schematic diagram of a method of cooling a product using a cooling system in accordance with the teachings of the present disclosure.

DETAILED DESCRIPTION

The cooling system of the present disclosure provides a rapid, on-demand solution to cooling or freezing products. Generally speaking, the cooling system as described herein receives a plurality of products in an unfrozen state and delivers the plurality of products in a refrigerated or frozen state. For simplicity, the cooling systems 100, 300 are described as cooling systems 100, 300 to produce multiple frozen products. However, the systems 100, 300 may also be used for cooling one or more products that do not reach a frozen state, but a cooled state, near-freezing state, or partially solid state.

Turning first to FIG. 1, a first exemplary cooling system 100 is assembled in accordance with the teachings of the present disclosure. The cooling system in this example is a freezer system 100 and includes an enclosed environment 104, a refrigeration system 108 for controlling the temperature of the enclosed environment 104, and a conveyor system 112 disposed in the enclosed environment 104 and in proximity to the refrigeration system 108. The enclosed environment 104 includes an inlet 116, an outlet 120, and an interior space 122 defined by a plurality of walls made of insulated panels 124, 128, 132, 136 (FIG. 3). An antechamber 140 and a receiving chute 144 are coupled to enclosed environment 104. The antechamber 140 at least partially surrounds the inlet 116 and the receiving chute 144 at least partially surrounds the outlet 120 of the enclosed environment 104. So configured, the conveyor system 112 receives a product at the antechamber 140, transports the product along a spiral travel path of the conveyor system 112 within the interior space 122 of the enclosed environment 104, and delivers a cooled or frozen product by depositing the cooled or frozen product through the receiving chute 144.

As illustrated in FIGS. 1-3, the enclosed environment 104 includes four side walls 124, 128, 132, 136, a roof 148, and a floor 152. The interior space 122 of the enclosed environment 104 may be accessed by an operator via one or more doors 156. In the illustrated example of FIG. 3, two doors 156 are disposed in the first and second side walls 124, 128 to access the refrigeration system 108. Each of the walls 124, 128, 132, 136, roof 148, floor 152, and doors 156 are preferably constructed using one or more connected insulated panels. The roof 148 may be constructed of one or more insulated panels joined together by an insulated frame. Similarly, each of the side walls 124, 128 (hidden for illustrative purposes in FIG. 1), 132, 136 may include a plurality of connected insulated panels where each panel is connected to a panel of the roof 148, a panel of the floor 152, and adjacent side wall panels by insulated frames. The walls of the antechamber 140 and receiving chute 144 may also be constructed of insulated panels and frames. The insulated frames may be a hybrid frame, such as the hybrid insulated frame disclosed in U.S. Pat. No. 10,246,873, filed Nov. 16, 2017, titled “Insulated Structural Members for Insulated Panels and a Method of Making Same,” U.S. application Ser. No. 16/663,910, filed on Oct. 25, 2019, titled “Method of Manufacturing Hybrid Insulation Panel,” and U.S. application Ser. No. 16/582,147, filed Sep. 25, 2019, titled “Hybrid Insulating Panel, Frame, and Enclosure,” which are hereby incorporated by reference. In other examples, the frames may be wood, metal, composite, foam, or a combination of materials.

Turning now in more detail to the cooling and temperature controls of the cooling system 100, the refrigeration system 108 is at least partially disposed within the interior space 122 of the enclosed environment 104 and adjacent to the conveyor system 112. The refrigeration system 108 cools the interior space 122 to freezing temperatures so that a product freezes before exiting the enclosed environment 104. The refrigeration system 108 includes a condenser (not illustrated) and an evaporator 164 and is controlled by a refrigeration control system. The refrigeration system 108 may maintain a temperature of the interior space 122 of the enclosed environment 104 in a temperature range of approximately negative 40 degrees Fahrenheit to approximately 30 degrees Fahrenheit, depending on the application. While the evaporator 164 is disposed in the interior space 122, the condenser may be disposed outside of the interior space 122 of the enclosed environment 104.

The control system is coupled to the refrigeration system 108 to monitor, analyze, and control the refrigeration system 108. The control system, which may be a smart refrigeration control system and located in the condenser, may be operated remotely or locally to change temperature, refrigeration cycle settings, or control and/or operate other functions of the refrigeration system 108. The control system may be communicatively coupled to one or more sensors attached to the evaporator 164 or disposed in other areas in the interior space 122 of the enclosed environment 104 to monitor the evaporator 164 and temperature at various locations within the cooling system 100. The control system may also include one or more processors and a memory for storing executable instructions that enables automatic operation of a defrost cycle and/or other features or programs of the refrigeration system 108. The condenser may be disposed outside of the enclosed environment 104 on the ground or on the roof 148 of the enclosed environment 104. In other examples, the refrigeration and control systems may be arranged differently. For example, the condenser and the control system may be mostly externally disposed relative to the enclosed environment 104. The evaporator 164 may be mostly disposed in the interior space 122 of the enclosed environment 104, partially disposed in the interior space 122 of the enclosed environment 104, or attached to any of the walls 124, 128, 132, 136, roof 148, floor 152, or doors 156 of the cooling system 100.

The conveyor system 112 of FIGS. 1-3 is arranged to transport one or more products in the freezing temperatures of the interior space 104 between the inlet 116 and the outlet 120 of the enclosed environment 104. As shown in FIGS. 2 and 3, the conveyor system 112 includes a conveyor path 182, a spiral support structure 186, a motor 190 (FIG. 2), and a diverter chute 194. The conveyor path 182 extends between the inlet 116 and the outlet 120 of the cooling system 100 and includes three main portions: an inlet portion 196, a spiral path 198, and an outlet portion 202. Generally speaking, by the time a product completes its travel path around the spiral path 198 (i.e., one cycle), the product is frozen or adequately as it reaches the outlet portion 202 of the conveyor path 182. The inlet portion 196 of the conveyor path 182 includes one or more conveyor belts that extends between an interior space 206 (FIG. 3) of the antechamber 140 and through the inlet 116 of the enclosed environment 104 to the spiral structure 186. The spiral structure 186 includes the spiral path 198 and a rotating drum 200, which enhances belt travel of the spiral path 198. The spiral path 198 extends in an ascending spiral between the input portion 196 and the output portion 202. The spiral path 198 may include one or more chains, links, or plated belts that rotate about a central axis A of the spiral structure 186. The outlet portion 202 of the conveyor system 112 includes one or more conveyor belts that extends from the spiral path 198, through the outlet 120 of the enclosed environment 104, and into an interior space 210 (FIG. 3) of the receiving chute 144.

The motor 190 of FIGS. 1 and 3 is a variable speed motor connected to the central axis A to control the rotation of the drum 200 of the spiral conveyor structure 186. The motor 190 is controlled by a variable frequency drive which is synchronous with a conveyor motor 201 located in the antechamber 140 (FIG. 3). The conveyor motor 201 in the antechamber 140 drives the circuitous conveyor belt from the inlet 116, through the spiral support structure 186, and to the outlet 120. The spiral support structure 186 may be partially enclosed in a frame 214 of vertical and horizontal panels. The frame 214 provides stability to the moving conveyor path 182 and also helps direct cool air toward the conveyor path 198.

As shown in FIGS. 2 and 3, the diverter chute 194 for recirculating the product is disposed in the conveyor path 182 of the conveyor system 112. The diverter chute 194 is entirely disposed in the interior space 122 of the enclosed environment 104 and extends at an angle from the outlet portion 202 of the conveyor path 182 to the inlet portion 196. An inlet end of the diverter chute 194 may be open (i.e., not blocked off) to return a product, that has completed its travel around the spiral travel path 198, back to the inlet portion 196 of the conveyor path 182 when the system 100 is in recirculation mode. Dispensing or recirculation mode is managed by a conveyor control system 218 located in a conveyor control panel (FIG. 2), that is accessible from outside of the cooling system 100. The diverter chute 194 also enables the system 100 to operate during off-hours, or hours when operators are not present. In such an example, the conveyor system 112 would keep running during off-hours to maintain the cool temperatures of the enclosed environment 104, repeatedly returning products to the inlet portion 196 after leaving the spiral travel path 198, and without causing the conveyor system 112 itself to freeze. Certain products may freeze within a single cycle, i.e., one complete trip along the spiral path 198. However, other products may need to complete additional cycles, i.e., more than one trip along the spiral path 198. In these cases, the product may be directed to pass into the diverter chute 194 instead of exiting the enclosed environment 104 through the outlet 120. In this case, the product is directed to slide down the diverter chute 194 and return to the inlet portion 196 of the conveyor path 182 to complete an additional freezing or cooling cycle. There may be additional structures placed in the conveyor path 182 leading to the diverter chute 194 to cause all products to return to the beginning of the freezing or cooling cycle (i.e., the inlet portion 196 of the conveyor path 182). The structures may be pneumatically or otherwise mechanically controlled via a control system of the conveyor system 112. However, the cooling system 100 may be programmed to extend the freezing cycle by adjusting the conveyor speed. Since the one or more conveyors of the conveyor path 182 has variable speed motors, slowing the conveyor speed would extend the period of time a product is in the enclosed environment 104.

Now turning to the exterior of the cooling system 100, the antechamber 140 and receiving chute 144 will now be described in more detail. The antechamber 140 and receiving chute 144 are attached to an exterior wall or surface of the enclosed environment 104 to provide temperature transitions between ambient and the freezing temperatures of the enclosed environment 104. The antechamber 140 and receiving chute 144 surround the inlet 116 and outlet 120 of the enclosed environment 104, respectively, and are aligned with the locations of the inlet and outlet portions 196, 202 of the conveyor path 182. The cooling system 100 of the present disclosure is configured to reduce energy transfer at the inlet 116 by controlling a temperature of the enclosed environment 104 in a first temperature range and a temperature of the antechamber 140 in a second temperature range. The second temperature range is approximately 20 degrees Fahrenheit above the temperature of the enclosed environment 104. The temperature in the antechamber 140 is influenced by one or more door heaters embedded beneath the door frames.

The antechamber 140 and receiving chute 144 may be constructed using similar insulative materials as the walls 124, 128, 132, 136, roof 148, and floor 152 of the enclosed environment 104. Both the antechamber 140 and receiving chute 144 of the illustrated system 100 protrude from one of the walls 132 of the enclosed environment 104. The antechamber 140 and/or the receiving chute 144 are constructed separately from the enclosed environment 104 and later attached, coupled, or otherwise connected to the enclosed environment 104. However, in other examples, one or both of the antechamber 140 and receiving chute 144 is structurally integrated with the overall structure of the enclosed environment 104. In all examples, the antechamber 140 may provide a separate, but connected environment relative to the enclosed environment 104 of the cooling system 100.

To reduce heat and vapor transfer at the inlet 116 of the enclosed environment 104, a pneumatic door 216 (FIG. 1) at an opening of the antechamber 140 may be operated to open the antechamber 140 to receive a product and close immediately behind the product. The automatic opening and closing of the door 216 to the antechamber 140 reduces the time the enclosed environment 104 is exposed to external temperatures (i.e., ambient). The pneumatic door 216 may be communicatively coupled to a source of the product so that the door 216 opens in anticipation of receiving the product from the source. In another example, the pneumatic door 216 may be coupled to one or more sensors disposed on the inlet portion 196 of the conveyor path 182 or in the interior compartment 206 (FIG. 3) of the antechamber 140 to sense the presence of a product. The sensors may then send a signal to a control system, which closes the door 216 once the product lands on the conveyor path 182. In yet another example, the pneumatic door 216 may be partially or entirely controlled by an operator. The door 216 or inlet 116 may be fitted with brush weather-stripping or other devices/materials to restrict the flow of heat and vapor from the outside environment into the interior 206 of the antechamber 240 and/or the enclosed environment 104.

The cooling system 100 may be designed to receive liquid-filled gel packs at the antechamber 140 and deliver cooled or frozen gel packs at the chute 144. As shown in FIG. 2, the inlet portion 196 of the conveyor path 182 extends into the interior space 206 of the antechamber 140 and is disposed at a first height H1 relative to a ground surface 220. In this way, the antechamber 140 may be sized and positioned so that a proprietary gel pack filling and sealing machine can deposit the formed and liquid-filled gel pack into the antechamber 140 and on to the conveyor path 182. The outlet portion 202 of the conveyor path 182 extends into the receiving chute 144 and is disposed at a second height H2 relative to the ground 220, where H2 is greater than H1. Accordingly, the receiving chute 144 is sized and positioned to receive a frozen product exiting the enclosed environment 104 through the outlet 120 via the outlet portion 202 of the conveyor path 182, and deliver the frozen product to a receiving bin disposed beneath the receiving chute 144.

As shown in FIG. 3, the inlet portion 196 of the conveyor path 182 extends into the antechamber 140 a first distance D1 and the outlet portion 202 of the conveyor path 182 extends into the interior 210 of the receiving chute 144 a second distance D2. In the illustrated example, the distance D1 is greater than D2 because the inlet portion 196 of the conveyor path 182 extends far enough into the antechamber 140 to catch a product being deposited, whereas the outlet portion 202 of the conveyor path 182 extends only far enough to drop the product through the chute 144. However, in other examples, a different structure, such as a slide or ramp, may be disposed in the antechamber 140 and configured to deliver a product through the inlet 116 and onto the conveyor path 182 disposed entirely in the enclosed environment 104. In yet another example, the inlet and outlet portions 196, 202 of the conveyor path 182 extend an equal distance out of the interior space 122 of the enclosed environment 104.

The antechamber 140 and receiving chute 144 of FIGS. 1-3 are configured to cooperate with an ascending spiral conveyor path 182. In the illustrated example, the antechamber 140 is coupled to an exterior wall of the cooling system 100, and specifically, the wall 132. The receiving chute 144 is also coupled to an exterior wall of the cooling system 100, and specifically, the wall 132. However, in other examples, the antechamber 140 and receiving chute 144 may be configured differently (e.g., size, shape, location) to cooperate with a different conveyor path 182. In one example, the outlet portion 202 of the conveyor path 182 may be disposed at the height H1 and the inlet portion 196 may be disposed at the height H2. In this example, the conveyor path 182 transports the product in a descending spiral before the frozen product exits the enclosed environment 104. The receiving chute 144 and the antechamber 140 would be placed in relation to the new positions of the inlet and outlet portions 196, 202 of the conveyor path 182. In another example, the antechamber 140 may be attached to the third wall 132, as shown in FIGS. 1-3, and the receiving chute 144 may be attached to a different wall in which the outlet is disposed, for example, the first wall 124, at the same or different heights relative to the ground 220.

As mentioned above, the cooling system 100 may also include a control system 218 for controlling the speed and direction of the movement of the conveyor system 112. The control system 218 is located within an electrical panel attached to the enclosed environment 104. The control system 218 may be locally or remotely accessed to increase and decrease the speed of the one or more conveyor belts of the conveyor system 112, start and stop movement of the conveyor belts, and even switch direction of the conveyor belts. For example, the speed of the conveyor path 182 may be changed depending on the time required to freeze a product. In operation, the one or more conveyor belts of the conveyor path 182 moves in a direction from the inlet 116 and toward the interior space 122 of the enclosed environment 104. The control system 218 may reverse the direction of the conveyor path 182 as needed. Additionally, the control system 218 may control access to the diverter chute 194 based on the product being processed by the cooling system 100. For example, the control system 218 may operate a number of freezing cycle programs stored in the memory of the processor. One freezing cycle program, for example, may be pre-programmed for processing a certain product. The program may be customized for freezing the particular product by having pre-stored settings related to conveyor speed, cooling temperature, and number of freezing cycles. The control system 218 can then operate the diverter chute 194 such that the products are diverted to the chute 194 for additional freezing cycles. The diverter chute 194 may be set up (e.g., via a program operated by a control system) according to number of products being processed so that each product being processed will run through the required number of cycles. After the last cycle is complete, the program will automatically remove the diverter chute 194 from the conveyor path 182 (i.e., by removing and diverting diverter arm in the conveyor path 182), permitting the frozen products to exit the enclosed environment 104.

The cooling system 100 may be configured to accommodate a particular space, environment, or to best suit the requirements of the product. In one example, the enclosed environment 104 may have a length (i.e., extending between the first and second side walls 124, 128) in a range of approximately 9 feet to approximately 10 feet, a height (i.e., extending between the floor 152 and the roof 148) in a range of approximately 9 feet to approximately 10 feet, and a width (i.e., measured between the third and four side walls 132, 136) in a range of approximately 17 feet to approximately 18 feet. However, in other exemplary enclosed environments, the construction and dimensions may vary. For example, the side walls 124, 128, 132, 136 may include a plurality connected insulated panels depending on the desired size and shape of the enclosed environment 104. In other words, the enclosed environment 104 may be customized based on the size of the spiral structure 186, freezing capacity, refrigeration system 108, conveyor system 112, and other factors of the cooling system 100. Additionally, the temperature settings of the system 100 may be customized to rapidly cool a product instead of freezing the product. The system 100 may be used for either rapidly cooling or rapidly freezing a product.

Turning now to FIGS. 4-9, a second exemplary cooling system 300 is assembled in accordance with the teachings of the present disclosure. The second exemplary cooling system 300 is similar to the first exemplary cooling system 100 of FIGS. 1-3, and also includes an enclosed environment 304 defined by insulated panels, a refrigeration system 308 disposed in the enclosed environment 304, and a conveyor system 312 directly exposed to cool air from the refrigeration system 308. Thus, for ease of reference, and to the extent possible, the same or similar components of the second exemplary cooling system 300 will retain the same reference numbers as outlined above with respect to the first exemplary cooling system 100, although the reference numbers will be increased by 200. The second exemplary cooling system 300 is described in more detail and in terms of various stations in which a product travels through the cooling system 300. For example, FIG. 5 illustrates a first station, FIG. 6 illustrates a second station, and FIGS. 7 and 8 illustrate a third station. FIG. 9 illustrates an exemplary freezable product 301 (i.e., capable of freezing) at the various stations of the cooling system 300.

Turning first to FIG. 4, the cooling system 300 is illustrated with a receiving bin 350 placed beneath an opening of a receiving chute 344 and a bagging machine 354 disposed above an opening of an antechamber 340. The antechamber 340 includes a pneumatic door 416 controllable to open to receive a freezable product and close immediately after the freezable product enters an interior compartment 406 (FIG. 9) of the antechamber 340. In this example, the bagging machine 354 locally injects a predetermined amount of water into each of a plurality of flat bags containing a powdered gel compound, then seals the water-filled bags, and deposits the filled bags, one by one, into the antechamber 340 through the pneumatic door 416. The bagging machine 354 includes wheels so that an operator may easily roll the bagging machine 354 into place above the opening of the antechamber 340. The bagging machine 354 is merely an exemplary freezable product source, and other systems may be used instead of the bagging machine 354 with the cooling systems 100, 300 of the present disclosure. For example, a conveyor of a packaging assembly for a freezable product may lead directly to the antechamber 340 for freezing and/or cooling. In yet another example, an operator may directly place freezable products into the antechamber 340 of the cooling system 300 to initiate the freezing or cooling process.

FIG. 5 illustrates the first station in the cooling system cycle of the cooling system 300. In FIG. 5, the interior space 406 of the antechamber 340 is illustrated. At the first station, a freezable product may be placed into the environmentally-controlled antechamber 340 and onto an inlet portion 396 of a conveyor path 382. The conveyor path 382 transports the freezable product through the inlet 316 of the enclosed environment 304 and to a spiral conveyor path 398 of the conveyor system 312. Also shown in FIG. 5 is a diverter chute 394, which may receive a freezable product before the freezable product exits the enclosed environment 304 to cycle through the spiral travel path 398 again. A diverter bracket may be placed on the outlet portion 402 of the conveyor path 382 leading to the diverter chute 394 to force the freezable product, which just completed a cycle around the spiral travel path 398, back to the first station of the cooling system 300 via the diverter chute 394. This may be set up based on the freezable product specifications, for example, if a freezable product requires more than one cycle.

FIG. 6 illustrates the second station in the cooling system cycle of the cooling system 300. At the second station, a freezable product moves onto the spiral pathway 398 of the conveyor system 112 travels in an ascending spiral. Along the spiral pathway 398, heat is removed from the bagged freezable product via the evaporator 364 to freeze the freezable product. When the system is freezing a plurality of products at one time, the spiral conveyor 398 effectively rotates the plurality of freezable products on the spiral pathways 398 directly in front of cool air from the refrigerated system 308. In this way, the spiral conveyor 398 disposes a plurality of freezable products on a smaller footprint in front of the evaporator 364. The conveyor system 312 utilizes vertical space to multiply the number of freezable products being processed. The spiral conveyor 398 also enhances freezing as the air from the evaporator 364 is in contact with multiple faces of the freezable product surface as it rotates around the spiral path 398. Heat conduction is the most efficient because of the molecule to molecule contact, however, other heat transfer processes are possible.

FIGS. 7 and 8 illustrate the third station in the cooling system cycle of the cooling system 300. In these figures, a side wall and the bagging machine 354 are removed for illustrative purposes, and an interior space 410 of the receiving chute 344 is shown. At the third station, the spiral pathway 398 ends, and a freezable product is transported to the outlet portion 402 of the conveyor path 382. As previously discussed, if a diverter is placed on or adjacent to the outlet portion 402 of the conveyor path 382, the freezable product will be diverted down the diverter chute 394 at the third station to return the freezable product to the first station. In the illustrated figures, however, no diverter is disposed in the conveyor path 382 at the third station, therefore the outlet portion 402 of the conveyor path 382 transports a freezable product through the outlet 320 of the enclosed environment 404 and into the receiving chute 344. As shown in FIG. 8, the receiving chute 344 may include angled guides 403 to safely transport a frozen product from the outlet 320 of the enclosed environment 304, through a pneumatically controlled exit door 405, and into the receiving bin 350. The exit door 405 is activated through a pneumatic cylinder via the control system to open when one or more frozen products is positioned in the receiving chute 344 following preprogrammed instructions. The door's open/close operation is engineered to limit the amount of heat and vapor that would flow in the interior space 410 of the receiving chute 344 from the outside environment. The door opening contains brush seals that minimize heat and vapor intrusion into the chute 344.

Operation of the second exemplary cooling system 300 of FIGS. 5-8 will now be described with reference to FIGS. 9 and 10. FIG. 9 illustrates a single freezable product 301 at and between various stations of the cooling system 300 (and as indicated using reference numbers 301A, 301 B, 301C, etc.), and FIG. 10 is a diagram of an exemplary method 500 or process of freezing a freezable product 301 in accordance with the teachings of the present disclosure. While the method 500 is described in connection with the second exemplary cooling system 300, the method 500 also applies to operating the first exemplary cooling system 100, as well. Additionally, the method 500 also applies to rapidly cooling a product without delivering a frozen product. However, to illustrate how the system 100, 300 may be used to deliver a frozen product, the terms “freezing,” “unfrozen,” “freezable,” and “frozen” are used below.

The method 500 includes a first step 510 of placing a freezable product 301 into the antechamber 340 of the cooling system 300. Placing the freezable product 301 into the antechamber 340 may include automatically opening the door 416 to the antechamber 340 to receive the freezable product 301 and immediately closing the door 416 after the freezable product 301 is disposed in the antechamber 340. The method 500 includes a step 520 of transporting the freezable product 301A into the enclosed environment 304. In the example shown in FIG. 9, the freezable product 301A is disposed on the inlet portion 396 of the conveyor path 382, which conveys the freezable product 301A into the interior space 322 of the enclosed environment 304 through the inlet 316. The inlet portion 396 of the conveyor path 382 transfers the freezable product 301 B to the spiral path 398 at the second station. In the illustrated example, the inlet portion 396 is a separate conveyor belt from the spiral path 398 but the path is continuous to ensure smooth processing. However, in other examples, the spiral path 398 and the inlet portion 396 are directly connected and form a single, continuous belt.

The method 500 further includes a step 530 of freezing the freezable product 301C, 301 D as the freezable product 301C, 301 D travels on the spiral travel path 398 in the enclosed environment 304. The freezable product 301C, 301 D travels in an ascending spiral as the refrigeration system 308 blows cool air toward the spiral structure 386. In some cases, the product is frozen by the time it reaches its highest point on the conveyor path 382. Finally, the method 500 includes a step 540 of delivering a frozen product 301E through the outlet 320 of the enclosed environment 304. The receiving chute 344 receives the frozen product 301E and directs the product through the door 405 and into the storage bin 350. The method 500 may also include setting, via a control system 418, a first temperature of the enclosed environment 304 and a second temperature of the antechamber 340. A higher temperature in the antechamber 340 and exit chute 344 may be desired when condensation and ice form from vapor entering the enclosed environment 304 from the outside environment, which impacts the operation of the conveyor belt and/or control system.

The cooling systems 100, 300 of the present disclosure may advantageously provide on-demand solutions to cooling or freezing products by packaging and cooling a product in a single location. Each of the cooling systems 100, 300 disclosed herein provides a simple, insulated structure that conveniently receives an unfrozen product and delivers a frozen or near-frozen product on the same side of the structure. In other examples, the inlet 116, 316 and outlet 120, 320 of the cooling systems 100, 300 may be located on different sides of the enclosed environment 104, 304 for other convenient purposes, as well. The insulated structure, or enclosed environment 104, 304 as described herein, is kept at cooling or freezing temperatures to sufficiently cool or freeze a product as the product ascends the spiral path 198, 398 before exiting the enclosed environment 104, 304. By providing an environmentally-controlled antechamber 140, 340 at the inlet 116, 316 of the enclosed environment 104, 304, the temperature of the enclosed environment 104, 304 can remain at lower temperatures and the refrigeration system 108, 308 efficiently runs on less energy at the lower temperatures. Additionally, the antechamber 140, 340 reduces the accumulation of moisture at the inlet 116, 316 and the evaporator 164, 364, thereby limiting instances of ice build-up across the inlet 116, 316 and on the coils of the evaporator 164, 364.

Preferred embodiments of this invention are described herein, including the best mode or modes known to the inventors for carrying out the invention. Although numerous examples are shown and described herein, those of skill in the art will readily understand that details of the various embodiments need not be mutually exclusive. Instead, those of skill in the art upon reading the teachings herein should be able to combine one or more features of one embodiment with one or more features of the remaining embodiments. Further, it also should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the invention. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the aspects of the exemplary embodiment or embodiments of the invention, and do not pose a limitation on the scope of the invention. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Claims

1. A system for cooling a product comprising:

an enclosed environment having an outlet, an inlet, and a temperature in a first temperature range;

an antechamber at least partially surrounding the inlet of the enclosed environment, the antechamber having a temperature in a second temperature range;

a conveyor system including a conveyor path extending between the inlet and the outlet of the enclosed environment and providing a spiral travel path; and

wherein the temperature range of the enclosed environment is configured to cool the product before the product exits through the outlet of the enclosed environment.

2. The system of claim 1, wherein the conveyor path includes an inlet portion disposed at a first height and an outlet portion disposed at a second height greater than the first height.

3. The system of claim 1, wherein the conveyor path includes an inlet portion at least partially disposed in the antechamber and extending through the inlet of the enclosed environment.

4. The system of claim 1, wherein the conveyor path moves in an ascending spiral.

5. The system of claim 1, wherein the antechamber includes a pneumatic door controllable to open and close to receive a product before the product enters the enclosed environment.

6. The system of claim 1, further comprising a refrigeration control system to control the temperature in the first temperature range and the temperature in the second temperature range.

7. The system of claim 1, further comprising a conveyor control system to control the speed of the conveyor path.

8. A system for cooling a product comprising:

an enclosed environment having an inlet and an outlet; and

a conveyor system including a conveyor path extending between the inlet and the outlet of the enclosed environment, the conveyor path including an inlet portion, an outlet portion, and a spiral portion connecting the inlet and outlet portions, the inlet portion being adjacent to the inlet of the enclosed environment and the outlet portion adjacent to the outlet of the enclosed environment;

wherein the spiral portion defines an ascending spiral travel path to transport a product from the inlet to the outlet of the enclosed environment.

9. The system of claim 8, further comprising an antechamber coupled to an exterior wall of the enclosed environment and at least partially surrounding the inlet of the enclosed environment.

10. The system of claim 9, wherein the antechamber includes a pneumatic door controllable to open and close to receive a product before the product enters the enclosed environment.

11. The system of claim 9, wherein the inlet portion of the conveyor path is at least partially disposed in the antechamber and extends through the inlet of the enclosed environment.

12. The system of claim 9, wherein the enclosed environment has a temperature in a first temperature range and the antechamber has a temperature in a second temperature range.

13. The system of claim 10, further comprising a refrigeration control system to control the temperature in the first temperature range and the temperature in the second temperature range.

14. The system of claim 8, further comprising a conveyor control system to control the speed of the conveyor path.

15. The system of claim 8, wherein the inlet portion of the conveyor path is disposed at a first height and the outlet portion of the conveyor path is disposed at a second height greater than the first height.

16. A method of cooling a product comprising:

placing a product in an antechamber connected to an inlet of an enclosed environment, the enclosed environment having the inlet, an outlet, and a conveyor disposed in the enclosed environment and extending from the inlet to the outlet;

transporting the product from the antechamber into the enclosed environment;

cooling the product as the product travels on a spiral travel path between the inlet and the outlet;

delivering a cooled product through the outlet of the enclosed environment.

17. The method of claim 16, setting, via a control system, a first temperature in a first temperature range of the enclosed environment and a second temperature in a second temperature range of the antechamber.

18. The method of claim 16, wherein cooling the product includes transporting the product between the inlet and the outlet in an ascending spiral travel path.

19. The method of claim 16, wherein placing a product in an antechamber includes automatically opening a door to the antechamber to receive the product and immediately closing the door after receiving the product.

20. The method of claim 16, wherein transporting the product includes conveying the product via a conveyor belt from the antechamber to the enclosed environment.