Apparatus and methods of forming a display case door and frame

• US 20020078654A1
• Filed: 06/09/2001
• Published: 06/27/2002
• Est. Priority Date: 06/09/2000
• Status: Active Grant

• Current Assignee: Anthony Incorporated (Dover Corporation)
• Original Assignee: Anthony Incorporated (Dover Corporation)
• Inventors: Carson, Timothy, Calderon, Raymundo, Richardson, Richard J., Nazarian, John, Nicholson, Jeffery, Crown, Charles E.
• Granted Patent: US 6,606,833 B2
• Time in Patent Office: Days
• US Class Current: 52/656.9
• CPC Class Codes: A47F 3/0434 Glass or transparent panels
• CPC Class Codes: A47F 3/125 Doors for show cases

Abstract

Perimeter frame rails and door frames rails are described for a more thermally efficient and cost-effective display case such as for refrigerated display cases. The frames are preferably formed from cold rolled steel. A perimeter frame may include first, second and third walls defining an opening or a recess that can be closed by a contact plate. A door for a refrigerated display case may include a glass unit and a forward portion extending inwardly from a perimeter frame edge portion toward an edge of the forward glass pane and a first side portion extends rearwardly to a groove. An insulating member insulates the door rail from the cold area and includes a portion engaging the groove. A glass door is also provided for a refrigerated display case having a first glass panel, a second glass panel, and low emissivity coatings on the inside surfaces of the first and second glass panels. One or more intermediate glass panels can also be included. Spacer assemblies are used to separate adjacent glass panels and preferably include a desiccant-embedded sealant. Preferably, little or no metal structures are used in the spacers.

Claims

1. A frame for an opening in a refrigerated display case for receiving and supporting one or more doors for allowing access into the case, the frame comprising:

a first wall extending rearwardly from a forward portion of the opening, a second wall extending from the first wall in a second direction and a third wall extending from the second wall in a direction different from the second direction to define a recess between the first, second and third walls;

a contact plate extending between the first and third walls closing the recess; and

wherein the first, second and third walls are formed from rolled steel and wherein at least one of the walls includes a bend in the wall.

2. A frame as in claim 1 further comprising a frame cover and insulation between the frame cover and at least one of the first, second and third walls.

3. A frame as in claim 2 wherein the frame cover is positioned on an interior surface of the frame between an inside of the display case and an outside surface of the frame.

4. A frame as in claim 2 where the frame cover includes a plurality of standoffs.

5. A frame as in claim 4 where the first, second and third walls include a plurality of grooves and wherein at least one of the standoffs extends into one of the grooves.

6. A frame as in claim 2 wherein the frame cover includes a surface for supporting a light source.

7. A frame as in claim 2 wherein the frame cover includes a surface for supporting a lens.

8. A frame as in claim 1 further comprising a fourth wall having a lip defining a groove.

9. A frame as in claim 8 further comprising a frame cover having an edge extending into the groove.

10. A frame as in claim 8 further comprising first and second frame elements each having a lip and a bridge element extending from the lip of the first frame element to the lip of the second frame element.

11. A frame as in claim 10 wherein each of the lips in the first and second frame elements define respective grooves and the bridge element is an angle plate having a first leg extending into the groove of the first frame element and a second leg extending into the groove of the second frame element.

12. A frame as in claim 11 further comprising a corner connecting element extending into the groove for allowing a corner of one frame element to be joined to a corner of an adjacent frame element.

13. A frame as in claim 1 where the first, second and third walls form a substantially rectangular recess.

14. A frame as in claim 13 wherein the first and third walls define an opening to the recess and wherein the frame further comprises a door contact plate extending across the opening.

15. A frame as in claim 13 further including a removable cover for extending from the first wall to the third wall for substantially covering the recess.

16. A frame as in claim 15 wherein the cover includes a surface for accepting a door contact plate.

17. A frame as in claim 1 further including a hinge support element wherein the hinge support element is surface mounted to the frame.

18. A frame as in claim 1 further including a hinge support element wherein the hinge support element includes at least one projection extending into an opening in the frame.

19. A frame as in claim 18 wherein the at least one projection is a registration pin engaging a complimentary opening in the frame.

41. The door of claim 1 wherein the first and second glass panels have widths and heights that are identical.

42. The door of claim 1 wherein at least one of the first and second spacer assemblies includes a sealant material having a desiccant embedded in the sealant material.

43. The door of claim 42 wherein the at least one spacer assembly has an inwardly-facing side, facing inwardly relative to the glass door, and wherein the desiccant-embedded sealant material extends along the inwardly-facing side of the at least one spacer assembly.

44. The door of claim 42 wherein the at least one spacer assembly includes an inside portion facing inwardly toward a center of the door and an outside portion outboard of the inside portion and further including a vapor impervious layer extending between the first glass panel and the second glass panel and between the inside and the outside portions.

45. The door of claim 44 wherein the vapor impervious layer is formed from a metal.

46. The door of claim 45 wherein the vapor impervious layer is formed from a metal foil.

47. The door of claim 44 wherein the vapor impervious layer is bonded to the adjacent glass panels by a sealant bead.

48. The door of claim 44 wherein the outside portion includes a sealant extending completely across the spacing between the first and second glass panels.

49. The door of claim 48 wherein the sealant extending completely across the spacing includes hot melt butyl.

50. The door of claim 44 wherein the outside portion further includes a stiffening structure extending longitudinally of the least one spacer assembly.

51. The door of claim 50 wherein the stiffening structure is formed from an ethylene propylene ter-polymer.

20. A mullion for combining with a perimeter frame for an opening in a refrigerated display case for receiving and supporting one or more doors for allowing access into the case, the mullion comprising:

at least first and second walls to define a recess between the first and second walls and formed from rolled steel and wherein at least one of the first and second walls includes at least one bend in the wall; and

a contact plate extending between the first and second walls closing the recess.

21. A mullion as in claim 20 further comprising a mullion cover and insulation between the mullion cover and at least one of the first and second walls.

22. A mullion as in claim 21 wherein the mullion cover is positioned on an interior surface of the mullion between an inside of the display case and an outside surface of the mullion.

23. A mullion as in claim 21 where the mullion cover includes a plurality of standoffs.

24. A mullion as in claim 23 where the first and second walls include a plurality of grooves and wherein at least one of the standoffs extends into one of the grooves.

25. A mullion as in claim 21 wherein the mullion cover includes a surface for supporting a light source.

26. A mullion as in claim 21 wherein the mullion cover includes a surface for supporting a lens.

27. A mullion as in claim 20 where the first and second walls and a third wall form a substantially rectangular recess.

28. A mullion as in claim 20 wherein the first and third walls define an opening to the recess and wherein the mullion further comprises a door contact plate extending across the opening.

29. A mullion as in claim 20 further including a removable cover for extending from the first wall to the third wall for substantially covering the recess.

30. A mullion as in claim 29 wherein the cover includes a surface for accepting a door contact plate.

31. A door for a refrigerated display case, the door comprising:

a glass unit including a forward glass pane and a rearward glass pane for allowing viewing of product within the display case;

a door frame for surrounding and supporting the glass unit;

the door frame being formed from rolled steel and including a perimeter frame edge portion and a forward portion extending inwardly from the perimeter frame edge portion toward an edge of the forward glass pane and a first side portion extending rearwardly from the perimeter edge portion and a second wall extending inwardly from the first side portion and a third wall together defining a groove; and

a plastic insulating assembly having at least one anchor portion extending into the groove.

32. A door as in claim 31 further comprising an insulating tape between the frame and the glass unit.

33. A door as in claim 31 wherein the plastic insulating assembly extends inwardly toward the glass unit and contacts the glass unit.

34. A door as in claim 31 wherein the forward portion and the second and third walls have lengths and wherein the second and third walls are shorter than the length of the forward portion and wherein the plastic assembly includes a projecting portion for projecting between the second wall and an edge of the rearward glass pane in the glass unit.

35. A door as in claim 34 wherein the frame further includes an interior wall having an end and extending between an edge of the rearward glass pane and the first side portion and wherein the projecting portion of the plastic assembly engages the end of the interior wall.

36. A door as in claim 31 further including a glazing channel encasing the forward and rearward glass panes.

37. A door as in claim 31 wherein the plastic wall portion includes an end portion extending inwardly toward the rearward glass pane.

38. A door as in claim 37 wherein the plastic wall end portion contacts the rearward glass pane.

39. A door as in claim 37 further including a glazing channel around edges of the rearward glass pane and wherein the plastic wall end portion contacts the glazing channel.

40. A glass door for a refrigerated display case, the door comprising:

a first glass panel having in inside and an outside surface;

a low emissivity coating on the inside surface of the first glass panel;

a second glass panel having in inside and an outside surface;

a low emissivity coating on the inside surface of the second glass panel;

an intermediate glass panel between the first and second glass panels;

a first spacer assembly between the first and intermediate glass panels and a second spacer assembly between the intermediate and second glass panels wherein the first and second spacer assemblies are formed from warm edge spacer assemblies; and

a frame extending about and supporting at least one of the glass panels.

52. The door of claim 40 wherein the frame extends about and supports all of the glass panels in the door.

53. The door of claim 52 wherein the frame includes a glazing strip contacting the outside surface of the second glass panel.

54. A glass door for a refrigerated display case, the door comprising:

a first glass pane having an inside surface and an outside surface;

a second glass pane having an inside surface and an outside surface;

a low emissivity coating on at least one of the inside surfaces of the first and second glass panes;

a spacer assembly between the first and second glass panes and including a desiccant embedded sealant on an inside portion of the spacer assembly; and

a frame extending about and supporting the first and second glass panels.

55. The glass door of claim 54 wherein the low emissivity coating is on the inside surface of the first glass pane.

56. The glass door of claim 54 wherein the low emissivity coating is tin oxide on the inside surface of the first glass pane.

57. The glass door of claim 54 wherein the low emissivity coating is on the inside surfaces of both the first and second glass panes.

58. The glass door of claim 54 wherein the spacer assembly includes a second sealant portion outside of the desiccant embedded sealant.

59. The glass door of claim 58 wherein the first and second glass panes are spaced apart a first distance and wherein the second sealant portion extends substantially the first distance between the first and second glass panes, and wherein the spacer includes a gas impervious wall extending substantially the first distance.

60. The glass door of claim 59 wherein the gas impervious wall is formed from a metal foil having first and second ends and further including sealant beads sealing ends of the metal foil to the adjacent glass panes.

61. The glass door of claim 59 wherein the gas impervious wall separates the second sealant portion from the desiccant embedded sealant.

62. The glass door of claim 54 wherein the spacer includes a support structure surrounded on at least three sides by at least two polymeric materials, wherein one of the polymeric materials includes the desiccant-embedded sealant and wherein the other polymeric material is a sealant, and wherein the support structure is formed from a material that has a hardness greater than a hardness of each of the at least two polymeric materials.

63. The glass door of claim 62 wherein the support structure is formed from an ethylene propylene ter-polymer.

64. The glass door of claim 63 wherein the at least two polymeric materials include hot melt butyl.

65. The glass door of claim 54 wherein the frame includes at least one hinge portion for allowing the door to swing open and closed.

66. A glass door for a refrigerated display case, the door comprising:

a first glass panel having an inside and an outside surface;

a low emissivity coating on the inside surface of the first glass panel;

a second glass panel having an inside and an outside surface;

a low emissivity coating on the inside surface of the second glass panel;

a third glass panel extending between and spaced apart from each of the first and second glass panels;

first and second spacers, wherein the first spacer separates the first and third glass panels and wherein the second spacer separates the second and third glass panels, wherein at least one of the first and second spacers includes an inside portion formed from a desiccant-embedded sealant, a metal foil extending between and sealed to the adjacent glass panels, a second sealant on a side of the metal foil opposite the desiccant-embedded sealant and extending between the adjacent glass panels, and a polymeric structure having a hardness greater than a hardness of the second sealant; and

a frame extending around and supporting the first, second and third glass panes and including a hinge assembly for allowing the door to open and close.

68. A door as in claim 67 further comprising a wall on the forward portion of the frame extending toward the rearward portion of the door frame.

69. A door as in claim 68 further comprising a corner key having a portion extending between the wall and the frame side wall.

70. A door as in claim 67 further comprising a wall extending from the rearward portion of the frame toward the forward portion of the door frame.

71. A door as in claim 70 further comprising a corner key having a portion extending between the wall and the frame side wall.

72. A door as in claim 70 wherein the insulating portion includes an engagement element for engaging the wall on the rearward portion of the frame.

73. A door as in claim 67 wherein the rearward wall includes an extension wall forming a groove.

74. A door as in claim 73 wherein insulating portion includes an engagement portion extending into the groove.

75. A door as in claim 67 wherein the insulating portion includes a first plastic portion and a second plastic portion having a hardness less than a hardness of the first plastic portion and wherein the second plastic portion contacts the rearward glass pane.

76. A door as in claim 67 wherein the rearward portion is spaced from and does not overlap any portion of the rearward glass pane.

77. A door as in claim 67 wherein the insulating portion and the forward portion of the frame extend over the glass unit approximately the same amount.

67. A door for a refrigerated display case, the door comprising:

a glass unit including a forward glass pane and a rearward glass pane for allowing viewing of product within the display case;

a door frame for surrounding and supporting the glass unit, at least one side of the door frame including a forward portion extending partly over a surface of the forward glass pane, a rearward portion extending inwardly toward the glass unit and rearward of the forward portion and a side wall extending between the forward portion and the rearward portion; and

an insulating portion engaging the rearward portion and extending from the rearward portion inwardly and contacting a surface of the rearward glass pane.