COOLING SYSTEM AND RELATED EQUIPMENT FOR REFRIGERATION UNITS

Abstract

A system includes a fan connecting to a refrigeration unit that provides air at a cooler temperature than that which is monitored in the refrigeration unit. The fan is activated when the temperature outside of the refrigeration unit is cooler than inside the refrigeration unit. A filter filters air that is forced into the refrigeration unit by the fan. A controller can turn on and off the fan and a compressor of the refrigeration unit. Flaps are provided to prevent air from entering the refrigeration unit when the fan is turned off, or the temperature outside the refrigeration unit is warmer than within the refrigeration unit.

Description

FIELD OF THE INVENTION

The invention relates to an auxiliary or supplemental cooling system for refrigeration units. The invention also relates to a kit that can be retrofitted onto a refrigeration unit.

SUMMARY

A system comprises a fan connecting to a refrigeration unit that provides air at a cooler temperature than that which is monitored in the refrigeration unit. The fan is activated when the temperature outside of the refrigeration unit is cooler than inside the refrigeration unit. A filter filters air that is forced into the refrigeration unit by the fan. A controller which can turn on and off the fan and a compressor of the refrigeration unit. Flaps to prevent air from entering the refrigeration unit when the fan is turned off, or the temperature outside the refrigeration unit is warmer than within the refrigeration unit.

In additional aspects of the invention, a system comprises a fan connecting to a refrigeration unit that provides air at a cooler temperature than that which is monitored in the refrigeration unit by a thermostat of the refrigeration unit. The fan is controlled by a thermostat that is independent of the thermostat of the refrigeration unit, such that the fan will be activated when the temperature detected by the thermostat associated with the fan is at or below a threshold value.

A kit comprising the components of claim 1. A kit comprising the components of any of the claims. A method of installing the components is also contemplated.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The present invention is described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention.

FIG. 1 shows a schematic view of an embodiment of the present invention;

FIG. 2 shows components in accordance with aspects of the present invention;

FIG. 3 shows a schematic of the present invention;

FIG. 4 shows an alternative wiring schematic and components in accordance with aspects of the present invention; and

FIG. 5 shows a cooling supply in accordance with aspects of the present invention.

DETAILED DESCRIPTION

The invention relates to an auxiliary or supplemental cooling system for refrigeration units. In embodiments, the cooling system provides considerable energy savings to existing refrigeration units and particularly industrial units, including, for example, refrigeration units used in supermarkets to maintain produce and other foodstuffs at a desired temperature. The present invention can also be implemented in mobile units such as those used in the transportation industry, e.g., retrofitted to a container, truck or railcar, for example.

In embodiments, the cooling system is used when outside temperatures are below the temperature of the refrigeration unit. In further embodiments, the present invention includes a controller and thermostat that can, for example, sense and/or monitor the temperature of the refrigeration unit and outside temperature and, when necessary, activate the cooling system in order to supplement the cooling unit of the refrigeration unit to maintain or increase the temperature within the refrigeration unit, as needed. The invention also relates to a kit that can be retrofitted onto a refrigeration unit.

In embodiments, the control system of the present invention, e.g., fan, can be completely independent of an existing control system of the compressor. That is, the fan of the present invention can be activated, independent of the control of the compressor. For example, a thermostat can be connected to the fan of the present invention, and another thermostat can be connected to the compressor. When the outside temperature is below a threshold level, e.g., 38° F., the fan of the present invention can be activated to cool the refrigerator unit. In this scenario, the compressor fan will not go on, since the refrigerator unit will be at a lower temperature than that which would activate the fan of the compressor. More specifically, when the fan of the present invention goes on due to the outside temperature being at or below a certain threshold, which is at a lower temperature than the temperature in the refrigerator, the compressor will not go on. However, when the outside temperature is above the threshold temperature, the fan of the present invention will not be activated (e.g., stay off), and the compressor fan will then be activated to cool the refrigerator unit, since the temperature inside the refrigerator unit would rise above the threshold value. In this way, the two fans can work independent, and there is no need to worry about integrating the circuitry of the compressor with that of the present invention. In this way, there is no way in which to void the warranty of the compressor or refrigerator unit.

In further embodiments, a relief duct can also be implemented with the present invention. The relief duct will ensure that there any pressure build up in the refrigerator unit is dissipated so that when the refrigerator unit is opened, e.g., the door is opened, the cool air will not rush out into the environment.

FIG. 1 shows a schematic view of an embodiment of the present invention. As shown in FIG. 1, a cooler or refrigeration unit 5 includes a compressor 10 and wiring logic 15. The cooler or refrigeration unit 5 can be any type of cooler or refrigeration unit. In implementation, a fan 20 is retrofitted to the refrigeration unit 5 and connected to the wiring logic 15 (and controller “C”). The fan 20 is located outside the cooler or refrigeration unit 5. In embodiments, the fan can be connected to outside ambient (e.g., outside of the building or transportation vehicle, etc.) by use of a conduit or pipe 25. The conduit or pipe 25 can be of any applicable size in order to provide cooler outside temperature to the cooler or refrigeration unit 5, depending on the size of the cooler or refrigeration unit 5. For example, the conduit or pipe 25 can be about 3 to 6 inches in diameter; although other dimensions are also contemplated by the present invention. In embodiments, such as used in the transportation industry, the fan can be located outside and there is no need for a conduit or pipe.

As further shown in FIG. 1, the wiring logic 15 provides power to the compressor 10 of the refrigeration unit 5, as well as the fan 20 of the present invention. The wiring logic 15 can also be connected to the controller “C”, which can include logic to turn on and off the fan 20 and compressor 10 at certain temperatures. For example, when the refrigeration unit 5 falls below a certain temperature and the temperature outside is cooler than that sensed and/or monitored in the refrigeration unit 5, the controller “C” will turn on the fan 5 in order to allow cooler temperature from outside to cool the refrigeration unit 5.

The controller “C” can be connected to thermostats “T” located within the refrigeration unit 5 and outside, either directly or though the wiring logic 15. In embodiments, the controller “C” will also control the compressor 10, in which case the controller “C” can shut off the compressor 10 when not needed, e.g., when the temperature increase can be provided by the present invention (activating the fan 5).

FIG. 2 shows the components of the present invention. In particular, FIG. 2 shows the fan 20 and conduit 25 (with related components). The fan 20 can include, for example, a screen or other safety component 30. In embodiments, the fan 20 can be about 3 to 6 inches in diameter; although other sizes are also contemplated by the present invention, depending on the cooling requirements of the refrigeration unit 5.

The fan 20 can be connected to the conduit 25, which leads to outside. The conduit includes mechanical flaps 35, which are hinge mounted 40 to the conduit 25. A filter 45 can also be fitted, coupled or otherwise attached to the conduit 25. In the case that the conduit is not needed, the components of the conduit can be connected directly to the fan, or a component of the fan.

In implementation, the flaps 35 are mechanical flaps which can be opened when the fan 20 is activated. This can be by simple air current. For example, the incoming air being forced into the refrigeration unit can open the mechanical flaps 35. However, when the fan is in the “off” state, the flaps 35 will be closed, and will not permit the outside air into the refrigeration unit. The conduits can also be insulated. Both or either of the closed flap and insulation will ensure that lower temperature air will not enter the refrigeration unit, when the fan is not activated. However, when the fan 20 is activated, the flaps 35 will open and allow the lower temperature air (temperature that is lower than in the refrigeration unit) to enter into the refrigeration unit, by way of the fan 20. The insulation of the conduit will also help to maintain the cooler air temperature entering into the refrigeration unit. It should be understood that the fan 20 will consume much less energy than the compressor 10, thus saving considerable energy and costs.

Although shown as hinge mounted, the flaps 35 can also be connected to actuators that are controlled by the controller “C”. The filter 45 can be any known filter, which is removable for cleaning or replacement.

Basically within the wiring logic, the power runs to the indoor thermostat. If the thermostat is calling for cold air then the power runs to the outdoor thermostat. If the outdoor temperature will satisfy the thermostat then the power is diverted to the fan. If not then the power would be diverted to the compressor. As should be understood in the art, this can be done with contactors and programmable logic.(low voltage energy management system.)

FIG. 3 shows a schematic of the present invention. More specifically, FIG. 3 shows a fan 20 mounted on an outside wall, e.g., to a conduit 25 leading to the refrigeration unit. The fan 20 is connected to an incoming power supply 50, which can be independently controlled from the compressor unit (shown in FIG. 1). Flaps 35 can be connected to the conduit 25 or other housing 55. The flaps 35 can be insulated flaps which ensures that cool air will not be lost to the outside. The filter 45 can be any known filter, which is removable for cleaning or replacement, and which is near a grill or other safety component 30.

FIG. 4 shows an alternative wiring schematic and components in accordance with aspects of the present invention. As shown in FIG. 4, a thermostat 65 is provided on an outside of the refrigeration unit 5, and a thermostat 70 is provide on an inside of the refrigeration unit 5. The thermostat 65 is operable to control the fan 25, outside of the refrigeration unit, and the thermostat 70 is operable to control the compressor. The thermostat 65 and thermostat 70 independently control each of the components, e.g., the fan 25 and the compressor, respectively. That is, the thermostat 65 controls the fan 25, independent of the compressor. Likewise, the thermostat 70 controls the compressor, independent of the fan 25. In this way, the present invention does not have to be integrated into the wiring controls and systems of the compressor, and thus will make installation easy and avoid voiding the warranty of the compressor and/or refrigeration unit 5.

In operation, the thermostats 65, 70 can activate the fan or the compressor at a certain threshold value, e.g., below 38° F. In this way, when the outside temperature is at or below the threshold value, the fan 65 will be activated, independent of the control of the compressor. In this way, the fan 65 can cool the refrigeration unit when the outside temperature is at or below a threshold level, e.g., 38° F. In this scenario, the compressor fan 70 will not go on, since the refrigerator unit 5 will be at a lower temperature than that which would activate the fan 70 of the compressor. More specifically, when the fan 65 of the present invention goes on, which was activated due to a lower temperature than the temperature of the refrigerator unit 5, the compressor fan 70 will not go on. However, when the outside temperature is above the threshold temperature, the fan 65 of the present invention will not be activated (e.g., stay off), and the compressor fan 70 will then be activated to cool the refrigerator unit 5, since the temperature inside the refrigerator unit would rise above the threshold value. In this way, the two fans can work independent, and there is no need to worry about integrating the circuitry of the compressor with that of the present invention.

In further embodiments, a relief duct 75 can be implemented with the present invention. The relief duct 75 can be in communication with the interior of the refrigeration unit 5, as shown in FIGS. 4 and 5. The relief duct 75 can release any positive pressure in the refrigeration unit 5 to ensure that any pressure build up in the refrigerator unit 5 is dissipated so that when the refrigerator unit 5 is opened, e.g., the door is opened, the cool air will not rush out into the inside environment. The relief duct 75 can be connected to the inside of the refrigeration unit 5 by a conduit 80. A grill 85 can be placed adjacent to the conduit 80, on an inside wall of the refrigeration unit, for example. Insulator flaps 90 can be provided on the conduit 80, which can act as the relief duct.

The present invention also includes a kit. The kit includes the components noted above. The kit may include other components on existing systems such as safety switches. The kit can include assembly instructions. The assembly instructions can include methods of installing the system, in addition to adjusting the controller.

The kit can be a standalone system, in which the electronics of the stand alone system do not have to be tied into the compressor 10 or other components of the existing refrigeration unit. In this case, the components of the present invention can include a thermostat that is set a couple or few degrees lower than the compressor temperature. This will ensure that the compressor 10 does not even turn on, when the temperature is below a certain temperature.

The method of installation can include provided a hole in the refrigeration unit and retroffiting the fan onto the refrigeration unit, in communication with the hole. The wiring and controller can be connected to the fan, mechanical flaps and temperature sensors (thermometers). Logic can be programmed for temperature settings, when to turn on and off the fan and/or compressor, open and close the flaps, and other operations of the present invention.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims, if applicable, are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principals of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. Accordingly, while the invention has been described in terms of embodiments, those of skill in the art will recognize that the invention can be practiced with modifications and in the spirit and scope of the appended claims.

Claims

1. A system comprising a fan connecting to a refrigeration unit that provides air at a cooler temperature than that which is monitored in the refrigeration unit by a thermostat of the refrigeration unit, the fan being controlled by a thermostat that is independent of the thermostat of the refrigeration unit, such that the fan will be activated when the temperature detected by the thermostat associated with the fan is at or below a threshold value.

2. The system of claim 1, further comprising a relief duct that dissipates positive pressure within the refrigeration unit.

3. The system of claim 1, wherein the thermostat of the refrigeration unit detects a temperature within the refrigeration unit above the threshold value and activates a compressor of the refrigeration unit.

4. The system of claim 3, wherein the fan is off when the thermostat of the refrigeration unit detects a temperature within the refrigeration unit above the threshold value.

5. The system of claim 1, wherein the fan is activated when the temperature outside of the refrigeration unit is cooler than inside the refrigeration unit.

6. The system of claim 1, further comprising a filter for filtering air being forced into the refrigeration unit by the fan.

7. The system of claim 1, further comprising a controller, which can turn on and off the fan and a compressor of the refrigeration unit.

8. The system of claim 1, further comprising flaps to prevent air from entering the refrigeration unit when the fan is turned off, or the temperature outside the refrigeration unit is warmer than within the refrigeration unit.

9. A kit comprising the components of claim 1.

10. (canceled)