REFRIGERATION DOOR SYSTEM AND DOOR ASSEMBLY WITH DEFROSTING AND RELATED METHODS

Abstract

A refrigeration door system has a defrosting feature. The refrigeration door system also includes a housing defining a refrigerated cavity therein, and a door assembly carried by the housing and providing access to the refrigerated cavity. The door assembly includes a door frame and door coupled to the door frame. The door switches between an open position providing the access to the refrigerated cavity and a closed position where the refrigerated cavity is inaccessible. The door frame includes gasket pieces carried by a first side member and a second side member. The gasket pieces are spaced apart and define an air channel. The refrigeration door system also includes a positive pressure source fluidly coupled to the top member and configured to output air, and a heating device configured to heat the air from the positive pressure source.

Description

TECHNICAL FIELD

The present disclosure relates to the field of walk-in coolers, and, more particularly, to a defrost apparatus for refrigeration doors and related methods.

BACKGROUND

Commercial coolers and freezers today are sufficiently large to accommodate workers inside them. Access is provided by a doorway having a door hingedly mounted in a frame. A persistent problem associated with cooler doors has been their propensity to freeze up. The cold inside surface of the door is moved into the warmer ambient air and causes condensation to form around the frame. Condensed water covers the surface of the frame so that when the door is closed the moisture that has formed on the surface of the frame can freeze and make opening the door difficult. Accordingly, there is a need that has long existed for a walk-in cooler having a door that is substantially less likely to freeze and yet maintains thermal integrity of the walk-in cooler.

SUMMARY

Generally, a refrigeration door system has a defrosting feature. The refrigeration door system also includes a housing defining a refrigerated cavity therein, and a door assembly carried by the housing and providing access to the refrigerated cavity. The door assembly includes a door frame and door coupled to the door frame. The door switches between an open position providing the access to the refrigerated cavity and a closed position where the refrigerated cavity is inaccessible. The door frame includes a top member having a first end and a second end opposite the first end, the top member having a top conduit therein, a first side member coupled transversely to the first end of the top member and having a first conduit therein, the first conduit being fluidly coupled to the top conduit, and a second side member coupled transversely to the second end of the top member and having a second conduit therein. The second conduit is fluidly coupled to the top conduit. The door frame also includes a plurality of orifices positioned along the first side member and the second side member and being adjacent to the door when in the closed position, and a plurality of gasket pieces carried by the first side member and the second side member. The plurality of gasket pieces is spaced apart and defines an air channel between each of the first side member and the second side member and adjacent portions of the door. The refrigeration door system also includes at least one positive pressure source fluidly coupled to the top member and configured to output air into at least first and second conduits and through the plurality of orifices, and at least one heating device configured to heat the air from the at least one positive pressure source.

In some embodiments, the first side member and the second side member each may include a port integrated within the door frame and being fluidly coupled respectively to the first conduit and the second conduit. The door may include first and second door sweeps carried on a bottom edge to define a longitudinal channel fluidly coupled to the first conduit and the second conduit when the door is in the closed position. Also, the door frame may include first and second air diverters respectively fluidly coupled to proximal ends of the first conduit and the second conduit.

Further, the at least one heating device may include first and second heating devices respectively positioned adjacent the first and second ends of the top member. Each heating device may include an elongate resistive heating device extending longitudinally in the top member.

In other embodiments, the at least one positive pressure source may include a single positive pressure source configured to output air into the top conduit, and the door frame may include a third air diverter within the top conduit and to direct air outward towards the first and second ends of the top member and into the first conduit and the second conduit. The at least one positive pressure source may include a fan, for example.

Another aspect is directed to a door assembly for a refrigeration door system with a defrosting feature. The door assembly also includes a door frame, and a door coupled to the door frame. The door switches between an open position providing access to a refrigerated cavity and a closed position where the refrigerated cavity is inaccessible. The door frame includes a top member having a first end and a second end opposite the first end, the top member having a top conduit therein, and a first side member coupled transversely to the first end of the top member and having a first conduit therein, the first conduit being fluidly coupled to the top conduit. The door frame also includes a second side member coupled transversely to the second end of the top member and having a second conduit therein, the second conduit being fluidly coupled to the top conduit, a plurality of orifices positioned along the first side member and the second side member and being adjacent to the door when in the closed position, and a plurality of gasket pieces carried by the first side member and the second side member. The plurality of gasket pieces is spaced apart and defining an air channel between each of the first side member and the second side member and adjacent portions of the door. The door assembly also includes at least one positive pressure source fluidly coupled to the top member and configured to output air into at least first and second conduits and through the plurality of orifices, and at least one heating device configured to heat the air from the at least one positive pressure source.

Yet another aspect is directed to a method for making a refrigeration door system with a defrosting feature. The method includes coupling a door assembly to be carried by a housing and providing access to a refrigerated cavity, the door assembly may include a door frame and a door coupled to the door frame, the door switching between an open position providing the access to the refrigerated cavity and a closed position where the refrigerated cavity is inaccessible. The door frame includes a top member having a first end and a second end opposite the first end, the top member having a top conduit therein, and a first side member coupled transversely to the first end of the top member and having a first conduit therein, the first conduit being fluidly coupled to the top conduit. The door frame also includes a second side member coupled transversely to the second end of the top member and having a second conduit therein, the second conduit being fluidly coupled to the top conduit, a plurality of orifices positioned along the first side member and the second side member and being adjacent to the door when in the closed position, and a plurality of gasket pieces carried by the first side member and the second side member. The plurality of gasket pieces is spaced apart and defining an air channel between each of the first side member and the second side member and adjacent portions of the door. The method also includes positioning at least one positive pressure source fluidly to be coupled to the top member and configured to output air into at least first and second conduits and through the plurality of orifices, and coupling at least one heating device to heat the air from the at least one positive pressure source.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic front elevational view of a defrost apparatus for refrigeration doors according to the present invention.

FIG. 2 is a schematic cross sectional view taken in the direction of line 2-2 of FIG. 1.

FIG. 2A is a detail view of a conduit of the defrost apparatus of FIG. 2.

FIG. 2B is a detail view of a plurality of orifices punched into a first side member and in communication with the conduit of FIG. 2A.

FIG. 3 is a schematic front elevational view of a top member, a first side member and a second side member of the defrost apparatus forming a door frame for a refrigeration door to be mounted.

FIG. 4 is a schematic of the door frame of FIG. 3 illustrating operation of the defrost apparatus.

FIG. 5 is a schematic diagram of a first embodiment of a door assembly, according to the present disclosure.

FIGS. 6A-6B are schematic top plan and schematic side views respectively of a resistive heater from the door assembly of FIG. 5.

FIG. 7 is a schematic bottom view of a second embodiment of the door assembly, according to the present disclosure.

FIG. 8 is a schematic side view of a door from the second embodiment of the door assembly of FIG. 7.

FIG. 9 is a schematic perspective view of a first member from the second embodiment of the door assembly of FIG. 7.

FIG. 10 is a schematic bottom view of the first member from the second embodiment of the door assembly of FIG. 7.

FIG. 11 is a schematic bottom perspective view of the first member from the second embodiment of the door assembly of FIG. 7.

FIG. 12 is a schematic perspective view of a top member from the second embodiment of the door assembly of FIG. 7.

FIG. 13 is a schematic perspective view of a third embodiment of the door assembly, according to the present disclosure.

FIG. 14 is a schematic perspective view of a fourth embodiment of the door assembly, according to the present disclosure.

FIG. 15 is a schematic perspective view of a top member from the fourth embodiment of the door assembly of FIG. 14.

FIG. 16 is a schematic perspective view of a proximal molding section from the fourth embodiment of the door assembly of FIG. 14.

FIG. 17 is a schematic perspective view of a distal molding section from the fourth embodiment of the door assembly of FIG. 14.

FIG. 18 is a schematic side view of a door sweep from the fourth embodiment of the door assembly of FIG. 14.

FIG. 19 is a schematic perspective view of a door sweep from the fourth embodiment of the door assembly of FIG. 14.

FIG. 20 is a schematic side view of a guide from the fourth embodiment of the door assembly of FIG. 14.

FIG. 21 is a schematic perspective view of an upper track from the fourth embodiment of the door assembly of FIG. 14.

FIG. 22 is a schematic cross-sectional view of the proximal molding section from the fourth embodiment of the door assembly of FIG. 14 along line 22-22.

FIG. 23A is a schematic cross-sectional view of the proximal molding section from a fifth embodiment of the door assembly along line 22-22.

FIG. 23B is a schematic cross-sectional view of the distal molding section from the fifth embodiment of the door assembly.

FIGS. 24-25 are perspective views of the first member from the fifth embodiment of the door assembly.

FIG. 26 is a perspective view of the first member and the top member from the fifth embodiment of the door assembly.

FIG. 27 is a schematic perspective view of a sixth embodiment of the refrigeration door system, according to the present disclosure.

FIG. 28 is a schematic perspective view of the closing device from the refrigeration door system of FIG. 27.

FIGS. 29 & 30 are schematic perspective views of the door from the refrigeration door system of FIG. 27.

FIGS. 31 & 32 are schematic perspective views of the first side member from the refrigeration door system of FIG. 27.

FIGS. 33 & 34 are schematic perspective views of the second side member from the refrigeration door system of FIG. 27.

FIG. 35 is a schematic perspective view of the door from the refrigeration door system of FIG. 27.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which several embodiments of the invention are shown. This present disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art. Like numbers refer to like elements throughout, and base 100 reference numerals are used to indicate similar elements in alternative embodiments.

Referring to FIG. 1, a defrost apparatus 100 for a refrigeration door according to the present disclosure is now described. The defrost apparatus 100 is designed for installation in a door opening of a freezer or cooler 102. The door 110 is typically attached to a first side member 106 with hinges 112a, 112b, 112c. A handle 114 is mounted to an opposing side of the hinges 112a, 112b, 112c to open and close the door 110.

The defrost apparatus 100 includes a top member 104 having a first end and a second end and having a top conduit 120 formed therein. The top member 104 also includes a vent opening 126 configured to be coupled to a heated air source.

As described above, the defrost apparatus 100 includes the first side member 106 that has a first end and a second end, where the first end is secured perpendicular to the first end of the top member 104. The first side member 106 also includes a first conduit 122 formed therein coupled to the top conduit 120. A second side member 108 has a first end and a second end, where the second end is secured perpendicular to the second end of the top member 104 and the second side member 108 has a second conduit 124 formed therein coupled to the top conduit 120. The top conduit 120, first conduit 122 and the second conduit 124 are continuous in order for air flow to readily pass through.

Referring now to FIG. 2, a schematic cross sectional view taken in the direction of line 2-2 of FIG. 1 is shown. The first side member 106 is secured between the door 110 and cooler 102. Similarly, the second side member 108 is secured between an opposing edge of the door 110 and the cooler 102. The first and second conduits 122, 124 are also illustrated as being formed by the respective side member 106, 108. As shown in FIG. 2B, a first inner wall 128 is used to form the first conduit 122, with the exterior walls of the first side member 106 forming the remaining boundary for the first conduit 122. The second conduit 124 is formed similarly with a second inner wall 129 and the exterior walls of the second side member 108.

In addition, the first side member 106 also includes a plurality of orifices 126a, 126b, 126c-126n in an exterior wall. The plurality of orifices 126a, 126b, 126c-126n are configured to blow heated air out from the respective top, first and second conduits 120, 122, 124.

A schematic of the defrost apparatus 100 is illustrated in FIG. 3 without showing the relationship of the cooler 102 and door 110 for clarity. As described above, the defrost apparatus 100 includes the top member 104 that has a first end 104a and an opposing second end 104b, and the top conduit 120. A first end 106a of the first side member 106 is secured perpendicular to the first end 104a of the top member 104. The second side member 108 has a first end 108a and a second end 108b, where the first end 108a is secured perpendicular to the second end 104b of the top member 104. The vent opening 126 is also formed in the top conduit 104 although the vent opening 126 could also be positioned within the first or second side members 106, 108. There could also be more than one vent opening 126. The vent opening 126 is coupled to a heated air source in order to provide heated air through the respective conduits 120, 122, 124 and out of the plurality of orifices 126.

FIG. 4 is a schematic illustrating operation of the defrost apparatus 100. A blower 132 is coupled to a supply conduit 134. The blower 132 is configured to provide heated air 130 through the supply conduit to the vent 126 formed in the top member 104. The vent 126 is in communication with the top conduit 104. As the heated air 130 is provided within the top conduit 120, the heated air 130 flows down to each of the first and second side members 106, 108. As the pressure increases within the respective conduits 120, 122, 124, the heated air 130 is forced out through the plurality of orifices 126. The plurality of orifices 126 are configured to direct the heated air 130 to between edges of the refrigeration door 110 and the top member 104 and the first and second side members 106, 108 (collectively, the door frame) in order to melt and prevent ice from forming. It will of course be appreciated by those skilled in the art that if it is desired to heat the bottom of the door 110 to further reduce the likelihood that the door 110 will be stuck because of freezing, then a conduit having additional orifices can be extended from the first and/or second conduit 122, 124 across the threshold to deliver heated air.

Referring now to FIGS. 5 & 6A-6B, a refrigeration door system 250 is now described. The refrigeration door system is equipped with a defrosting feature. The refrigeration door system includes a housing 251 defining a refrigerated cavity 252 therein, and a door assembly 230 carried by the housing and providing an access to the refrigerated cavity. The door assembly 230 illustratively includes a door frame 231, and a door 232 coupled to the door frame and configured to switch between a first position closing the access and a second position opening the access.

The door frame 231 illustratively comprises a top member 238, a first side member 233, and a second side member 234. Each of the top member 238, and the first and second side members 233-234 has a first end and a second end.

The top member 238 has a top conduit 235 therein. The first end of the first side member 233 is coupled transversely to the first end of the top member 238. The first side member 233 illustratively includes a first conduit 236 therein and is fluidly coupled to the top conduit 235.

The first end of the second side member 234 is coupled transversely to the second end of the top member 238. The second side member 234 illustratively comprises a second conduit 237 therein and is fluidly coupled to the top conduit 235.

The door assembly 230 illustratively comprises a positive pressure source 240 (e.g. a powered fan or impeller) fluidly coupled to the top conduit 235 and configured to blow heated air into the top conduit and to the first and second conduits 236-237, and a plurality of orifices 241a-241d positioned along lower portions of the first side member 233, and the second side member 234 configured to exit the heated air out therefrom.

The door assembly 230 illustratively comprises an air diverter 242 fluidly coupled to an output of the positive pressure source 240 and configured to route pressurized air down opposite ends of the top conduit 235. The first end of the top conduit 235 illustratively comprises a first corner deflector 243a, and the second end of the top conduit 235 illustratively comprises a second corner deflector 243b.

The door assembly 230 illustratively comprises a threshold conduit 244 extending between the second ends of the first and second side members 233-234. Also, the second ends of the first and second side members 233-234 illustratively comprise third and fourth corner deflectors 243c-243d, which are fluidly coupled to the threshold conduit 244. In some embodiments, the third and fourth corner deflectors 243c-243d and the threshold conduit 244 may be omitted.

The door assembly 230 illustratively comprises a first downward exhaust vent 245a coupled to the first conduit 236, and a second downward exhaust vent 245b coupled to the second conduit 237. It should be appreciated that the first downward exhaust vent 245a and the second downward exhaust vent 245a in conjunction with the threshold conduit 244 are configured to prevent frost buildup on the threshold of the door 232.

The door assembly 230 illustratively comprises first and second heaters 246a-246b flanking the air diverter 242 and for heating the output of the output of the positive pressure source 240. In some embodiments, for example, as depicted in FIG. 6, the first and second heaters 246a-246b each comprises a resistive heating element extending longitudinally and respectively within opposite ends of the top conduit 235. In particular, each of the first and second heaters 246a-246b comprises an L-shaped resistive heater configured to extend within the top conduit 235.

Referring again to FIGS. 5 & 6A-6B, a refrigeration door system 250 according to the present disclosure is now described. The refrigeration door system 250 illustratively includes a housing 251 defining a refrigerated cavity 252 therein, and a door assembly 230 carried by the housing and providing access to the refrigerated cavity. The refrigeration door system 250 has a defrosting feature for preventing ice and frost buildup around the frame of the door assembly 230. Advantageously, the prevention of frost build-up enhances safety.

The door assembly 230 comprises a door frame 231 and door 232 coupled to the door frame. The door frame 231 includes a top member 238 having a first end and a second end opposite the first end. The top member 238 has a top conduit 235 therein. The door frame 231 also includes a first side member 233 coupled transversely to the first end of the top member 238 and having a first conduit 236 therein. The first conduit 236 is fluidly coupled to the top conduit 235.

The door frame 231 also includes a second side member 234 coupled transversely to the second end of the top member 238 and having a second conduit 237 therein. The second conduit 237 is fluidly coupled to the top conduit 235. In other words, the top conduit 235, the first conduit 236, and the second conduit 237 are all fluidly coupled. The door frame 231 illustratively comprises a plurality of orifices 241a-241d positioned along the first side member 233 and the second side member 234. In some embodiments, the plurality of orifices 241a-241d may extend along the entire length of the first side member 233 and the second side member 234. Moreover, in some embodiments, the plurality of orifices 241a-241d may extend along partially or entirely the length of the top member 238. It should be appreciated that when the door 232 is in the closed position, the plurality of orifices 241a-241d are positioning at the peripheral flange of the door.

The door assembly 230 also includes a positive pressure source 240 (e.g. a motorized blower/fan) fluidly coupled to the top conduit 235 and configured to output air into the top conduit and the first and second conduits 236, 237 and through the plurality of orifices 241a-241d. The positive pressure source 240 may comprise a single positive pressure source, and a third air diverter 242 within the top conduit 235 and to direct air outward towards the first and second ends of the top member 238 and down the first and second conduits 236, 237.

The door assembly 230 also includes a heating device configured to heat the air from the positive pressure source 240. More specifically, the heating device illustratively includes first and second heating devices 246a-246d respectively positioned adjacent the first and second ends of the top member 238. As perhaps best seen in FIGS. 6A-6B, each heating device 246a-246d comprises a pair of electrical connection terminals 254a-254b, and an elongate resistive heating element 255 coupled to the pair of electrical connection terminals and extending longitudinally in the top member 238.

The first side member 233 and the second side member 234 each comprises an angled port 245a-245b fluidly coupled to respectively to the first conduit 236 and the second conduit 237. The angled port 245a-245b is adjacent a floor 253. The door assembly 230 comprises a threshold conduit 244 extending between the first side member 233 and the second side member 234 and under the door 232. The door assembly 230 illustratively includes first and second air diverters 243a-243b fluidly coupled to respectively to proximal ends of the first conduit 236 and the second conduit 237. The door assembly 230 illustratively includes third and fourth air diverters 243c-243d fluidly coupled to respectively to distal ends of the first conduit 236 and the second conduit 237.

The first and second air diverters 243a-243b are configured to reduce air flow resistance in the transition turn from the top conduit 235 to the first and second conduits 236, 237, respectively. The third and fourth air diverters 243c-243d are configured to reduce air flow resistance in the transition turn from the first and second conduits 236, 237, respectively, to the threshold conduit 244. In some embodiments, each diverter 243a-243d may each comprise a plate angled at 45° (±10°) with respect to the longitudinal axis of the top member 238, but may alternatively comprise tubular turn connectors (i.e. a hollow tube shaped in a right angle).

Another aspect is directed to a method for making a refrigeration door system 250 with a defrosting feature. The method includes coupling a door assembly 230 to be carried by a housing 251 and providing access to a refrigerated cavity 252. The door assembly 230 includes a top member 238 having a first end and a second end opposite the first end, the top member having a top conduit 235 therein, and a first side member 233 coupled transversely to the first end of the top member and having a first conduit 236 therein, the first conduit being fluidly coupled to the top conduit. The door assembly 230 includes a second side member 234 coupled transversely to the second end of the top member 238 and having a second conduit 237 therein, the second conduit being fluidly coupled to the top conduit, and a plurality of orifices 241a-241d positioned along the first side member 233 and the second side member 234. The method includes positioning a positive pressure source 240 to be fluidly coupled to the top conduit 235 and configured to output air into the top conduit and the first and second conduits 236, 237 and through the plurality of orifices 241a-241d. The method comprises coupling a heating device to heat the air from the positive pressure source 240.

Referring now additionally to FIGS. 7-12, another embodiment of the door assembly 330 is now described. In this embodiment of the door assembly 330, those elements already discussed above with respect to FIGS. 5 & 6A-6B are incremented by 100 and most require no further discussion herein. This embodiment differs from the previous embodiment in that this door assembly 330 illustratively omits the threshold conduit 244 of FIG. 5.

In FIGS. 7-9, the bottommost portion of the door 332 illustratively includes a door sweep 357 comprising first and second molding sweeps 360, 361, which define a longitudinal channel 363 between opposing ends of the door. The door sweep 357 also comprises a third molding 364 spaced apart from the first and second molding sweeps 360, 361. As can be seen, the first side member 333 includes a first output port 356a fluidly coupled to the first conduit 336, and the second side member 334 includes a second output port 356b fluidly coupled to the second conduit 337. When the door 332 is in a closed position, the first and second output ports 356a-356b are aligned with the longitudinal channel 363. Therefore, heat air will flow through the longitudinal channel 363 and prevent ice buildup on the threshold. The longitudinal channel 363 feature may be in addition to or in alternative (as depicted) to the above noted threshold conduit 344

In FIG. 10-11, the second end/bottommost portions of the first side member 333 is shown, which shows the third air diverter 343c. As perhaps best seen in FIGS. 10-11, the door frame portion adjacent an inner most edge defines a thin cavity 365 extending along the length of the first side member 333 and being fluidly coupled to the first conduit 336. Helpfully, this prevents frost build-up on door frame.

In FIG. 12, the top member 338 is shown with the first and second heaters removed. Helpfully, this embodiment is readily serviced, permitting easy replacement of the first and second heaters, and cleaning of the air diverter 342.

Referring now additionally to FIG. 13, another embodiment of the door assembly 430 is now described. In this embodiment of the door assembly 430, those elements already discussed above with respect to FIGS. 5 & 6A-6B are incremented by 200 and most require no further discussion herein. This embodiment differs from the previous embodiment in that this door assembly 430 illustratively has the plurality of orifices 441a-441g with a spacing therebetween. Here, the spacing of the plurality of orifices 441a-441g on the first side member and the second side member may decrease moving away from the top member. This same spacing pattern may be repeated on the second side member (not shown). As will be appreciated, this feature enhances system air flow resistance.

Referring now additionally to FIGS. 14-22, a sliding door embodiment of the door assembly 530 is now described. The sliding door assembly 530 comprises a door frame 531, and a sliding door 532 slidingly carried by the door frame and switching between open and closed positions. As perhaps best seen in FIG. 15, the sliding door assembly 530 comprises an upper track 533 coupled to the door frame 531 and for slidingly carrying the door 532.

The door frame 531 illustratively comprises first and second members 534, 538, a medial member 535 extending substantially parallel (i.e. ±10° of parallel) to and between the first and second members, and a top member 536 extending between the first and second members and being coupled to the medial member. The door assembly 530 further comprises a proximal molding section 537 carried by a proximal end of the sliding door 532, and a distal molding section 540 carried by the first member 534. When the sliding door 532 is in the closed position, the proximal molding section 537 is aligned with the medial member 535, and the distal molding section 540 is aligned with a distal edge of the sliding door. The door assembly 530 further comprises an upper molding section 541 carried by the top member 536.

As perhaps best seen in FIG. 15, the distal molding section 540 illustratively includes first and second distal molding sweep strips 542a-542b, and the upper molding section 541 also comprises first and second distal molding sweep strips 543a-543b. The distal molding section 540 comprises a U-shaped molding channel extending vertically, and the upper molding section 541 comprises a U-shaped molding channel extending laterally. When the sliding door 532 is closed, the distal molding section 540 defines a first conduit, and the upper molding section 541 defines a top conduit.

As perhaps best seen in FIG. 22, the proximal molding section 537 illustratively includes first and second proximal molding sweep strips 544a-544b on an outer surface of the sliding door 532, and third and fourth proximal molding sweep strips 544c-544d on an inner surface of the sliding door 532. When the sliding door 532 is closed, the proximal molding section 537 cooperates with the medial member 535 to define a second pair of conduits 554a-554b (FIG. 22). As perhaps best seen in FIGS. 18-19, the sliding door 532 illustratively includes door sweeps 545a-545b carried on a bottom edge to define a longitudinal channel fluidly coupled to the first conduit and the second conduit when the sliding door 532 is in the closed position, thereby preventing frost build-up on the threshold of the sliding door.

The door assembly 530 illustratively comprises a first positive pressure source 546a fluidly coupled to the proximal molding section 537 when the door 532 is in the closed position, and a second positive pressure source 546b fluidly coupled to the distal molding section when the door is in the closed position. The door assembly 530 comprises first and second heaters 547a-547b respectively adjacent the first and second positive pressure sources 546a-546b. Each of the proximal molding section 537 and the distal molding section 540 defines a vertical channel for passage of heated air when the door 532 is in the closed position.

As perhaps best seen in FIG. 20, the sliding door 532 illustratively includes a longitudinal guide 550 coupled to the medial member 535 and for engaging a proximal edge of the sliding door. The longitudinal guide 550 extends vertically between the top member 536 and the floor. The longitudinal guide 550 is angled away from the proximal molding section 537 to avoid ware thereon from repeated opening and closing of the sliding door 532. In some embodiments, the proximal molding section 537 may comprise first and second proximal molding sweep strips 544a-544b with magnetic devices therein for coupling to the sliding door 532 as it passes through. Also, as shown in FIG. 19, the door frame 531 illustratively includes a sweep 551 carried by the medial member 535 and to engage the sliding door 532 and remove frost from an outer surface of the sliding door.

As perhaps best seen in FIG. 21, the upper track 533 illustratively includes a plurality of arm pairs 552a-552d, and a channel body 553 coupled to the plurality of arm pairs and defining a longitudinal channel for slidingly receiving the sliding door 532. It should be appreciated, the sliding door 532 comprises a plurality of sliding devices (e.g. wheels, ball bearings) at an uppermost end and to be positioned in the longitudinal channel.

Referring now additionally to FIGS. 23A-23B & 24-26, another embodiment of the door assembly 630 is now described. In this embodiment of the door assembly 630, those elements already discussed above with respect to FIGS. 14-22 are incremented by 100 and most require no further discussion herein. This embodiment differs from the previous embodiment in that this door assembly 630 illustratively includes a first proximal molding sweep strip 644a coupled to a proximal edge of the sliding door 632, and second proximal molding sweep strip coupled to the medial member 635 and adjacent the refrigerated cavity 652. The door assembly 630 illustratively includes a third proximal molding sweep strip 644c coupled to the medial member 635 adjacent the exterior of the door assembly 630. As shown, when the sliding door 632 is in the closed position, the first and second molding sweep strip 644a-644b define a medial conduit 654 for passing heated air to prevent accumulation of ice/frost. This distal molding section 640 illustratively includes a singled molding sweep strip coupled to the first side member 634.

As perhaps best seen in FIGS. 24-25, the first side member 634 illustratively includes an external conduit 665 fluidly coupled to the first conduit 667 and having an outlet 666 adjacent the floor. The external conduit 665 is configured to direct heated air towards the door sweeps (not shown) carried on a bottom edge of the sliding door 632 to define a longitudinal channel fluidly when the sliding door is in the closed position, thereby preventing frost build-up on the threshold of the sliding door. Here, the external conduit 665 extends within the first conduit 667 and has an air collector 668 coupled to a distal end thereof. The air collector 668 may comprise an air funnel or air intake device configured to drive the air into the external conduit 665. In some embodiments, the external conduit 665 may run directly to an outlet of the heated air source.

As perhaps best seen in FIG. 26, the door assembly 630 further comprises an upper molding section 641 carried by the top member 636, and a distal molding section 640 carried by the first side member 634. When the sliding door 632 is in the closed position, the proximal molding section 637 is aligned with the medial member 635, and the distal molding section 640 is aligned with a distal edge of the sliding door.

Referring now additionally to FIGS. 27-35, another embodiment of the refrigeration door system 750 is now described. In this embodiment of the refrigeration door system 750, those elements already discussed above with respect to FIGS. 5 & 6A-6B are incremented by 500 and most require no further discussion herein. The refrigeration door system 750 is equipped with a defrosting feature. The refrigeration door system includes a housing (not shown) defining a refrigerated cavity therein, and a door assembly 730 carried by the housing and providing an access to the refrigerated cavity. The door assembly 730 illustratively includes a door frame 731, and a door 732 coupled to the door frame. The door 732 switches between an open position providing the access to the refrigerated cavity and a closed position where the refrigerated cavity is inaccessible. The door frame 731 includes a top member 738 having a first end and a second end opposite the first end. The top member has a top conduit 735 therein. The door frame 731 includes a first side member 733 coupled transversely to the first end of the top member and having a first conduit 736 therein, the first conduit being fluidly coupled to the top conduit 735, and a second side member 734 coupled transversely to the second end of the top member and having a second conduit 737 therein. The second conduit 737 is fluidly coupled to the top conduit 735. The door frame 731 also includes a plurality of orifices 741a-741d positioned along the first side member 733 and the second side member 734 and being adjacent to the door 732 when in the closed position, and a plurality of gasket pieces 770a-770d carried by the first side member 733 and the second side member 734. The plurality of gasket pieces 770a-770d is spaced apart and defines an air channel between each of the first side member 733 and the second side member 734 and adjacent portions of the door 732 when the door is in the closed position. Each of the plurality of gasket pieces 770a-770d may comprise a cold resistant elastomeric material. Helpfully, the air channel extends around the periphery of the door 732 and prevents frost buildup.

The refrigeration door system 750 also includes one or more positive pressure sources (not shown) fluidly coupled to the top member 738 and configured to output air into at least first and second conduits 736-737 and through the plurality of orifices 741a-741d, and one or more heating devices (not shown) configured to heat the air from the one or more positive pressure sources.

The first side member 733 and the second side member 734 each illustratively includes a port 771a-771b integrated within the door frame 731 and being fluidly coupled respectively to the first conduit 736 and the second conduit 737. Of course, in other embodiments, the ports 771a-771b may be omitted, or only included on one side member rather than both.

As perhaps best seen in FIG. 30, the door 732 illustratively comprises first and second door sweeps 760-761 carried on a bottom edge to define a longitudinal channel 763 fluidly coupled to the first conduit 736 and the second conduit 737 when the door 732 is in the closed position. The second door sweep 761 (facing outward and away from the refrigerated cavity) has a height less than a height of the first door sweep 760 (facing inward towards the refrigerated cavity), and this creates an exit outlet for the heated air to exit outside the refrigeration door system 750, rather than within the refrigerated cavity.

The door frame 731 illustratively comprises a closing mechanism 772 coupled between the second side member 734 and the door 732. The closing mechanism 772 is configured to bias the door 732 to return the closed position, and illustratively includes, for example, a coil spring device, and an arm.

In some embodiments, the door 732 comprises a framed internal structure comprising longitudinal segments extending internally along the periphery, and a housing carrying the longitudinal segments therein. The housing may comprise a durable material, for example, a plastic material (e.g., thermos molded). The door 732 also comprises foam insulation within the housing, and a metal plating 773 (e.g., textured plating such as diamond plating) extending along the side edges of the housing, which provides for a durable edge.

It should be appreciated that the features of each of the door assemblies 100, 230, 330, 430, 530, 630, 730 may be combined in multiple fashions.

Many modifications and other embodiments of the present disclosure will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the present disclosure is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.

Claims

1. A refrigeration door system with a defrosting feature, the refrigeration door system comprising: a housing defining a refrigerated cavity therein; anda door assembly carried by the housing and providing access to the refrigerated cavity;the door assembly comprising a door frame and door coupled to the door frame, the door switching between an open position providing the access to the refrigerated cavity and a closed position where the refrigerated cavity is inaccessible,the door frame comprising a top member having a first end and a second end opposite the first end, the top member having a top conduit therein,a first side member coupled transversely to the first end of the top member and having a first conduit therein, the first conduit being fluidly coupled to the top conduit,a second side member coupled transversely to the second end of the top member and having a second conduit therein, the second conduit being fluidly coupled to the top conduit,a plurality of orifices positioned along the first side member and the second side member and being adjacent to the door when in the closed position, anda plurality of gasket pieces carried by the first side member and the second side member, the plurality of gasket pieces being spaced apart and defining an air channel between each of the first side member and the second side member and adjacent portions of the door,at least one positive pressure source fluidly coupled to the top member and configured to output air into at least first and second conduits and through the plurality of orifices, andat least one heating device configured to heat the air from the at least one positive pressure source.

2. The refrigeration door system of claim 1 wherein the first side member and the second side member each comprises a port integrated within the door frame and being fluidly coupled respectively to the first conduit and the second conduit.

3. The refrigeration door system of claim 2 wherein the door comprises first and second door sweeps carried on a bottom edge to define a longitudinal channel.

4. The refrigeration door system of claim 3 wherein the port of the first and second side members is fluidly coupled to the longitudinal channel when the door is in the closed position.

5. The refrigeration door system of claim 1 wherein the door frame comprises first and second air diverters respectively fluidly coupled to proximal ends of the first conduit and the second conduit.

6. The refrigeration door system of claim 1 wherein the at least one heating device comprises first and second heating devices respectively positioned adjacent the first and second ends of the top member.

7. The refrigeration door system of claim 6 wherein each heating device comprises an elongate resistive heating device extending longitudinally in the top member.

8. The refrigeration door system of claim 1 wherein the at least one positive pressure source comprises a single positive pressure source configured to output air into the top conduit; and wherein the door frame comprises a third air diverter within the top conduit and to direct air outward towards the first and second ends of the top member and into the first conduit and the second conduit.

9. The refrigeration door system of claim 1 wherein the at least one positive pressure source comprises a fan.

10. A door assembly for a refrigeration door system with a defrosting feature, the door assembly comprising: a door frame;a door coupled to the door frame, the door switching between an open position providing access to a refrigerated cavity and a closed position where the refrigerated cavity is inaccessible;the door frame comprising a top member having a first end and a second end opposite the first end, the top member having a top conduit therein,a first side member coupled transversely to the first end of the top member and having a first conduit therein, the first conduit being fluidly coupled to the top conduit,a second side member coupled transversely to the second end of the top member and having a second conduit therein, the second conduit being fluidly coupled to the top conduit,a plurality of orifices positioned along the first side member and the second side member and being adjacent to the door when in the closed position, anda plurality of gasket pieces carried by the first side member and the second side member, the plurality of gasket pieces being spaced apart and defining an air channel between each of the first side member and the second side member and adjacent portions of the door,at least one positive pressure source fluidly coupled to the top member and configured to output air into at least first and second conduits and through the plurality of orifices; andat least one heating device configured to heat the air from the at least one positive pressure source.

11. The door assembly of claim 10 wherein the first side member and the second side member each comprises a port integrated within the door frame and being fluidly coupled respectively to the first conduit and the second conduit.

12. The door assembly of claim 11 wherein the door comprises first and second door sweeps carried on a bottom edge to define a longitudinal channel.

13. The door assembly of claim 12 wherein the port of the first and second side members is fluidly coupled to the longitudinal channel when the door is in the closed position.

14. The door assembly of claim 10 wherein the door frame comprises first and second air diverters respectively fluidly coupled to proximal ends of the first conduit and the second conduit.

15. The door assembly of claim 10 wherein the at least one heating device comprises first and second heating devices respectively positioned adjacent the first and second ends of the top member.

16. The door assembly of claim 15 wherein each heating device comprises an elongate resistive heating device extending longitudinally in the top member.

17. The door assembly of claim 10 wherein the at least one positive pressure source comprises a single positive pressure source configured to output air into the top conduit; and wherein the door frame comprises a third air diverter within the top conduit and to direct air outward towards the first and second ends of the top member and into the first conduit and the second conduit.

18. A method for making a refrigeration door system with a defrosting feature, the method comprising: coupling a door assembly to be carried by a housing and providing access to a refrigerated cavity, the door assembly comprising a door frame and a door coupled to the door frame, the door switching between an open position providing the access to the refrigerated cavity and a closed position where the refrigerated cavity is inaccessible;the door frame comprising a top member having a first end and a second end opposite the first end, the top member having a top conduit therein,a first side member coupled transversely to the first end of the top member and having a first conduit therein, the first conduit being fluidly coupled to the top conduit,a second side member coupled transversely to the second end of the top member and having a second conduit therein, the second conduit being fluidly coupled to the top conduit,a plurality of orifices positioned along the first side member and the second side member and being adjacent to the door when in the closed position, anda plurality of gasket pieces carried by the first side member and the second side member, the plurality of gasket pieces being spaced apart and defining an air channel between each of the first side member and the second side member and adjacent portions of the door;positioning at least one positive pressure source fluidly to be coupled to the top member and configured to output air into at least first and second conduits and through the plurality of orifices; andcoupling at least one heating device to heat the air from the at least one positive pressure source.

19. The method of claim 18 wherein the first side member and the second side member each comprises a port integrated within the door frame and being fluidly coupled respectively to the first conduit and the second conduit.

20. The method of claim 19 wherein the door comprises first and second door sweeps carried on a bottom edge to define a longitudinal channel fluidly coupled to the first conduit and the second conduit when the door is in the closed position.