Refrigerated Case with a Self-Contained Condensate Removal System
20190133341 ยท 2019-05-09
Inventors
Cpc classification
F25D21/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25D2321/1413
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25D2321/1412
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
A preferred embodiment utilizes the waste heat from a refrigerant cycle to aid in the removal of condensate from a refrigerated case used primarily by grocery stores. Certain embodiments use a heating element to boil off condensate or a pump to remove the condensate. Another embodiment utilizes a wicking element and a shroud that directs hot air from the condenser through the wick thereby increasing the condensate evaporation rate. Yet another embodiment utilizes the hot gas tube from the refrigeration system routed through the bottom of the condensate tray to pre-heat the condensate to accelerate evaporation. Alternative embodiments combine certain features to create even more efficient system such as a heating element used with the wick system or the hot gas system used with the wick system. In some embodiments, a mold and mildew inhibitor is added to the condensate to maintain cleanliness.
Claims
1. A condensate removal system for a refrigerated case, comprising: a condensate pan configured to collect condensate from the refrigerated case; a fan; and an evaporative wick positioned in the condensate pan and comprising: a material having wicking properties, and horizontal airflow passages configured to allow air to flow through the evaporative wick, wherein the evaporative wick is located in the condensate pan such that a bottom of the evaporative wick comes into contact with the condensate collected by the condensate pan, and wherein the fan is configured to cause air to flow through the evaporative wick.
2. The refrigerated case as recited in claim 1, wherein the material of the evaporative wick comprises a material selected from the group consisting of silica, polyester, and Teflon.
3. The refrigerated case as recited in claim 1, wherein the material of the evaporative wick comprises a material selected from the group consisting of rayon cellulose, cotton, and wool.
4. The refrigerated case as recited in claim 1, further comprising a shroud configured to duct airflow generated by the fan to the evaporative wick.
5. The refrigerated case as recited in claim 1, further comprising a heating element configured to kill mold, mildew, and bacteria in the condensate pan.
6. The refrigerated case as recited in claim 1, further comprising a dispenser and a dispenser tube, the dispenser and the dispenser tube configured to add a mold and mildew inhibitor solution to the condensate collected in the condensate pan.
7. The refrigerated case as recited in claim 1, further comprising heating means to heat the condensate collected in the condensate pan.
8. The refrigerated case as recited in claim 7, wherein the heating means comprises a heating element.
9. The refrigerated case as recited in claim 7, wherein the heating means comprises a hot gas tube configured to direct waste heat through the condensate pan.
10. A refrigerated case, comprising: a refrigerated space; a condensate pan configured to collect condensate from the refrigerated space; a fan; and an evaporative wick positioned in the condensate pan and comprising: a material having wicking properties, and horizontal airflow passages configured to allow air to flow through the evaporative wick, wherein the evaporative wick is located in the condensate pan such that a bottom of the evaporative wick comes into contact with the condensate collected by the condensate pan, and wherein the fan is configured to cause air to flow through the evaporative wick.
11. The refrigerated case as recited in claim 10, wherein the material of the evaporative wick comprises a material selected from the group consisting of silica, polyester, and Teflon.
12. The refrigerated case as recited in claim 10, wherein the material of the evaporative wick comprises a material selected from the group consisting of rayon cellulose, cotton, and wool.
13. The refrigerated case as recited in claim 10, further comprising a shroud configured to duct airflow generated by the fan to the evaporative wick.
14. The refrigerated case as recited in claim 10, further comprising a dispenser and a dispenser tube, the dispenser and the dispenser tube configured to add a mold and mildew inhibitor solution to the condensate collected in the condensate pan.
15. The refrigerated case as recited in claim 10, further comprising a heating element configured to heat the condensate collected in the condensate pan.
16. The refrigerated case as recited in claim 15, further comprising an early leak detection system comprising at least one sensor, the early leak detection system configured to shut down a compressor and energize the heating element in response to a predetermined level of condensate in the condensate pan.
17. The refrigerated case as recited in claim 16, configured to reset and return to normal operation in response to a predetermined normal operating level of condensate after the compressor is shut down.
18. The refrigerated case as recited in claim 15, wherein the heating element is activated periodically to kill mold, mildew, and bacteria in the condensate pan.
19. A refrigerated case, comprising: a refrigerated space; an air inlet; an air outlet; a compressor; a condensate collection pan configured to collect condensate from the refrigerated space; a refrigeration system having a controller and configured to remove heat from the refrigeration cycle and remove condensate from the condensate collection pan; a condensate removal system, comprising: a fan, and a wicking element positioned in the condensate collection pan and configured to absorb condensate and to allow airflow generated by the fan to pass through a plurality of airflow passages in the wicking element; and a leak detector located at a high point of the condensate collection tray and configured to generate a high point signal in response to the presence of liquid at the high point of the condensate collection pan, wherein the high point signal from the leak detector causes the compressor to automatically shut down.
20. The refrigerated case as recited in claim 19, wherein the leak detector is further configured to return the refrigerated case to normal operation in response to a predetermined normal operating level of condensate after the compressor is shut down.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
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DETAILED DESCRIPTION
[0029] Referring initially to
[0030] Referring now to
[0031]
[0032]
[0033]
[0034] High volume pump 54 is used to pump condensate from the condensate tray 52. Condensate is produced by the evaporator coil located in refrigerated spaces 14 and 34. The condensate typically drips off the coils of the evaporator where it is collected and directed to condensate tray 52 through condensate drain 58. During normal operation in a high humidity location or a floral refrigeration system, the amount of condensate produced may exceed traditional methods of condensate removal, such as boiling off the condensate using a heating element. The failure to remove all produced condensate results in ongoing and routine maintenance that removes the collected condensate and may lead to the formation of mold and mildew. The use of high volume pump 54 allows the use of flexible hose or tubing 56 to direct the condensate out of refrigerated cases 10 and 30 to a location having a drain. Pump 54 provides sufficient output pressure that the condensate can be pumped up to a height above the refrigeration case then horizontally to an appropriate drain location. Since flexible hose or tubing 56 is used, the hose or tubing 56 may be routed as necessary to reach the drain location. Such an implementation allows refrigerated cases 10 and 30 to be placed a various locations in a store without the need to consider where to drain the condensate since the hose or tubing 56 is flexible and may be routed as necessary. In an alternative embodiment, refrigeration system 40 may also consist of a heating element 62 (not shown, see
[0035] Referring now to
[0036]
[0037] To aid in condensate removal, the airflow generated by fan 42 is ducted by shroud 68 through condenser 41 to wick 64, where the air passes through airflow passages 65 which run horizontally through wick 64. The airflow through airflow passages 65 of wick 64 evaporates condensate absorbed by wick 64. In a preferred embodiment, the wick 64 may be made by any material known in the art to exhibit wicking properties including capillary action, including but not limited to silica, polyester, Teflon, and other synthetic materials. Also, many natural materials, such as rayon cellulose, cotton and wool, are suitable materials for acceptable wicking properties for the present invention. Wick 64 includes air passages which run horizontally through the body of the wick 64 to facilitate the exposure of the wetted wicking material to the air as it passes through the wick 64. The particular size and shape of the wick passages 65 as shown in
[0038] The increased temperature of the airflow, resulting from the heat given off by condenser 41, increases the rate of condensate evaporation. After the airflow exits wick 64, the airflow exits the rear of refrigerated cases 10 and 30 through air outlet 16 in air outlet cover 24. In certain embodiments of the present invention, air outlet cover 24 provides a portion of shroud 68 to direct airflow to wick 64. This design also allows for quicker and easier access to the refrigeration components during maintenance. Fan 42 may be configured to operate when compressor 44 is deactivated, thereby allowing fan 42 to continue generating air flow through wick 64 to continue removing condensate.
[0039] Refrigeration system 90, similar to refrigeration system 80, utilizes heat controller 60, level sensor 63, and heating element 62. Heating element 62 can be used to supplement the condensate removal effect of wick 64. Heating element 62 also aids in the prevention of mold and mildew by periodically energizing heating element 62 to raise the temperature of any standing condensate in condensate tray 52 to an appropriate level to kill mold, mildew, and any other bacteria that may exist in the condensate. Since refrigeration system 90 utilizes waste heat to aid in the removal of condensate, the amount of time and power used by heating element 62 is greatly reduced thereby reducing the overall amount of power consumed by refrigeration system 90. Further, since the overall power requirements are reduced, standard power connections may be used to operate the systems without the need for additional power connections or high voltage connections. Such power reductions allow refrigerated cases 10 and 30 to operate within established guidelines for power consumption and efficiency.
[0040] In certain embodiments of the present invention, a dispenser 66 and dispenser tube 67 are utilized to allow for the addition of a mold and mildew inhibitor solution to the condensate. Since wick 64 will also absorb the inhibitor solution along with the condensate, mold and mildew will also be prevented within the structure of wick 64. As discussed above, heating element 62 may also be energized on a periodic basis, or as needed, to aid in the prevention of mold and mildew in condensate tray 52 and wick 64. The prevention of mold and mildew is especially critical in the grocery business due to the offensive nature of the odors produced by molds and mildews. Since refrigerated cases 10 and 30 take in and expel air, any mold or mildew smells generated within the cases 10 and 30 will be spread throughout the store.
[0041]
[0042] In operation, any condensate that collects in condensate tray 52 through condensate drain 58 is heated by the waste heat transferred from hot gas tube 70, thereby increasing the rate of evaporation. Since hot gas is generated at all times during operation of compressor 44, waste heat is continually transferred to any condensate accumulated in condensate tray 52. As a result, the amount of time required for heating element 62 to operate is reduced, if not eliminated. This use of waste heat to evaporate condensate and reduced run time for heating element 62 allows refrigerated cases 10 and 30 to operate within prescribed energy consumption limits.
[0043] Also shown in
[0044] Also shown in
[0045] Moisture sensor 74 is configured to sense the present of moisture, not just the presence of standing liquid. Since moisture sensor 74 is located outside of condensate tray 52, it should not sense the presence of any moisture. However, due to differing operating conditions, moisture sensor 74 may be configured to sense some moisture without generating an alarm condition.
[0046] The presence of moisture inside refrigerated cases 10 and 30 may lead to the formation of mold and mildew, which typically produces an offensive odor. Moisture sensor 74 provides an indication that moisture has formed outside of refrigeration system 100, which may be due to an overflow condition of condensate tray 52 or a leak from another portion of refrigerated cases 10 and 30.
[0047] Referring now to
[0048] As shown in
[0049] It is to be appreciated by someone skilled in the art that different styles of refrigerated cases, such as double refrigerated case 30 (see
[0050] Referring now to
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[0052] In operation, refrigerated cases 10 communicate with local server to transmit case status as well as receive operational commands, similar to system 200 discussed above. Refrigerated cases 10 having the wireless transceiver 310 allow for easier placement of refrigerated cases 10 without the need to use a hardwire connection to local network 302. An operator may interface with server 308 to program temperature set points for each refrigerated case 10 collectively, individually, or in sub-groups.
[0053] Moving now to
[0054] Each server 410 connects to the internet/cloud 402 through communication link 408, which may be any type of connection including WAN, cellular, Ethernet, Frame Relay, Fiber Optic, or any other communication protocol known in the industry. Also connected to internet cloud 402 is remote computer 404, which connects to internet/cloud 402 through a communication link 406, which is any communication protocol known in the industry, similar to servers 410. An operator of remote computer 404 accesses each server 410 through internet/cloud 402 to receive status information and send operational commands, such as raising and lowering temperature set points for each refrigerated case 10.
[0055] Alternatively, a remote control and monitoring server 414 (shown in dashed lines) may be located in the internet/cloud 402, which communicates directly with local servers 410. In this configuration, remote server continually communicates with local servers 410 to send and receive status information and operational commands. The remote computer 404 then connects with remote server 414 to monitor status information and adjust desired set points or other features of system 400. In this alternative configuration, remote computer 404 may also connect directly to each local server 410 to send and receive status information and operational commands.
[0056] Local networks 206, 302, and 412 may be any type of networking topology known in the industry, such as Ethernet, RS232/422/485, wireless, or other point-to-point or multi-drop technology.
[0057] It is to be appreciated by someone skilled in the art that various portions of the various embodiments described above may be combined to create a more efficient system. For example but without limitation, refrigeration system 100 may also incorporate wick 64 and shroud 68 to create a system capable of operation in a high temperature and high humidity environment without the need for additional power connections, drains, or the routing of tubing through the grocery space. Another example is dispenser 66 and dispenser tube 67 may be used with refrigeration systems 40, 80, and 100 without departing from the scope and spirit of the present invention. Further, since the above discussed systems are designed to remove condensate at an increased rate, maintenance requirements are minimized since accumulated condensate will not need to be removed manually.
[0058] While there have been shown what are presently considered to be preferred embodiments of the present invention, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope and spirit of the invention.