Spacer for a warehouse rack-aisle heat transfer system

Abstract

A spacer for use in stacking a plurality of cases containing a quantity of product on a pallet to form a pallet assembly and to facilitate heat transfer to or from the product is described. Installations for retaining a quantity of product at a desired temperature including a storage warehouse space including a rack-aisle heat transfer system incorporating pallet assemblies including spacers of the present disclosure are also described. The spacer of the present disclosure is useful to transfer heat to and from a quantity of warehouse product through both conduction and forced convection. The spacers provide an airflow path through at least one airflow channel between opposing sides of the pallet assembly so that airflow is not lost through sides adjacent to the opposing sides of the pallet assembly. The spacers further provide a consistent support surface for cases positioned above and below the spacers.

What is claimed is: 
     
         1 . An installation for maintaining a quantity of product at a desired temperature, comprising:
 a plurality of pallet assemblies;   a storage warehouse space having a plurality of racks sized for receiving the plurality of pallet assemblies arranged in rows and columns on racks, the pallets assemblies loaded with a quantity of product to be maintained at the desired temperature, each of said plurality of racks positioned adjacent to an aisle, whereby a forklift can access each of the plurality of pallets assemblies;   at least one air handler operably connected to said warehouse space to condition an ambient air in said warehouse space, said at least one air handler having an output sufficient to maintain a temperature of the ambient air in said warehouse space at a desired temperature;   at least one air flow chamber in fluid communication with a plurality of air intake openings formed through each of said plurality of racks;   at least one fan in fluid communication with said at least one air flow chamber, said fan operable to create a circulation of the ambient air flowing through said plurality of air intake openings, into said at least one air flow chamber and back to said warehouse space;   at least one of said plurality of pallet assemblies comprising:
 a pallet; 
 a plurality of cases containing the quantity of product; and 
 at least one spacer, each said spacer comprising:
 a substantially planar first surface extending in an x-y plane of a Cartesian coordinate system, said planar first surface formed of a first surface material, said planar first surface defining a spacer outer perimeter of a size and shape about congruent to the outer perimeter of the pallet; 
 a substantially planar second surface formed of a second surface material; and 
 a plurality of supports extending between said first surface and said second surface along a trajectory having a directional component along a z-axis of the Cartesian coordinate system, whereby each of said plurality of supports space said first surface from said second surface, said first surface, said second surface and said supports defining at least one airflow channel, said at least one airflow channel spanning a pair of opposing sides of said at least one spacer, wherein one of said pair of opposing sides of said at least one spacer comprises an airflow inlet and the other of said pair of opposing sides of said at least one spacer comprises an airflow outlet, whereby an airflow enters said at least one airflow channel at said airflow inlet, traverses said channel and exits said channel at said airflow outlet to define an airflow trajectory from said inlet to said outlet along an x-axis of the Cartesian coordinate system, whereby said plurality of supports substantially preclude the airflow from exiting said channel along a trajectory defined by the y-axis of the Cartesian coordinate system; 
 
 each of said plurality of cases stacked on said pallet of one of said plurality of pallet assemblies in a plurality of case layers, each of said plurality of case layers separated from another of said plurality of case layers by one of a plurality of said spacers; and 
   said at least one of said plurality of pallet assemblies received on one of said plurality of racks and associated with one of said plurality of air intake openings, whereby said circulation created by said at least one fan causes the airflow through the channel in the at least one spacer.   
     
     
         2 . The installation of  claim 1 , wherein said at least one airflow channel comprises a plurality of airflow channels. 
     
     
         3 . The installation of  claim 1 , wherein said first surface and said second surface are both coated with polytetrafluorethylene. 
     
     
         4 . The installation of  claim 1 , wherein said first surface material forming said substantially planar first surface of said at least one spacer has a thermal conductivity of at least 3 W/m·K, and wherein said second surface material forming said substantially planar second surface of said at least one spacer has a thermal conductivity of at least 3 W/m·K. 
     
     
         5 . The installation of  claim 1 , wherein said first surface material forming said substantially planar first surface of said at least one spacer has a thermal conductivity of at least 5 W/m·K, and wherein said second surface material forming said substantially planar second surface of said at least one spacer has a thermal conductivity of at least 5 W/m·K. 
     
     
         6 . The installation of  claim 1 , wherein said first surface material forming said substantially planar first surface of said at least one spacer has a thermal conductivity of at least 10 W/m·K, and wherein said second surface material forming said substantially planar second surface of said at least one spacer has a thermal conductivity of at least 10 W/m·K. 
     
     
         7 . The installation of  claim 1 , wherein said at least one air handler comprises a chiller operable to maintain the temperature of the ambient air in said warehouse space at the desired temperature of −5° F. to −30° F. 
     
     
         8 . The installation of  claim 1 , wherein said spacer outer perimeter substantially defines a rectangle measuring about 40 inches by about 48 inches. 
     
     
         9 . The installation of  claim 1 , wherein said spacer outer perimeter substantially defines a rectangle measuring about 42 inches by about 48 inches. 
     
     
         10 . The installation of  claim 1 , wherein said spacer outer perimeter substantially defines a rectangle measuring about 41 inches by about 48 inches. 
     
     
         11 . The installation of  claim 1 , wherein said spacer defines a load capacity for the quantity of product of about 1800 pounds. 
     
     
         12 . The installation of  claim 1 , wherein said spacer defines a load capacity for the quantity of product of about 3600 pounds. 
     
     
         13 . The installation of  claim 1 , wherein said first surface includes a plurality of perforations, said perforations are arranged such that at least one area of continuous surface free of said perforations and sized to receive a suction gripping device is provided on said first surface, said at least one area of continuous surface free of said perforations and sized to receive the suction gripping device comprising an area of 4 sq. in. 
     
     
         14 . The installation of  claim 1 , wherein said first surface and said second surface are both formed of an aluminum material. 
     
     
         15 . The installation of  claim 1 , wherein said first surface and said second surface are both formed of a polycarbonate material. 
     
     
         16 . The installation of  claim 1 , wherein said first surface comprises a first surface of a first 14 gauge aluminum plate and said second surface comprises a first surface of a second 14 gauge aluminum plate. 
     
     
         17 . The installation of  claim 1 , wherein said first surface and said second surface are both formed of a 304 stainless steel material. 
     
     
         18 . The installation of  claim 1 , wherein said first surface and said second surface are both formed of a mild steel. 
     
     
         19 . The installation of  claim 1 , wherein said first surface and said second surface are both formed of a polymer. 
     
     
         20 . The installation of  claim 1 , wherein said supports are spaced from each other by about 4-6 inches measured along the y-axis of the Cartesian coordinate system, and wherein said supports extend along a trajectory defined by the z-axis to a height of about 0.25 to 3 inches. 
     
     
         21 . The installation of  claim 1 , wherein said spacer further comprises a lip extending from said spacer outer perimeter. 
     
     
         22 . The spacer of  claim 1 , wherein said first surface and said second surface are both coated with polytetrafluorethylene. 
     
     
         23 . A spacer for supporting a plurality of cases on a pallet, each of said plurality of cases containing a quantity of product to be maintained at a desired temperature, the spacer comprising:
 a substantially planar first surface extending in an x-y plane of a Cartesian coordinate system, said planar first surface formed of a first surface material, said planar first surface defining a spacer outer perimeter of a size and a shape about congruent to the outer perimeter of the pallet;   a substantially planar second surface formed of a second surface material; and   a plurality of supports extending between said first surface and said second surface along a trajectory having a directional component along a z-axis of the Cartesian coordinate system, each of said plurality of supports spacing said first surface from said second surface, said first surface, said second surface and said supports defining at least one airflow channel, said at least one airflow channel spanning a pair of opposing sides of said spacer, wherein one of said pair of opposing sides of said spacer comprises an airflow inlet and the other of said pair of opposing sides of said spacer comprises an airflow outlet, whereby an airflow enters said at least one airflow channel at said airflow inlet, traverses said channel and exits said channel at said airflow outlet to define an airflow trajectory from said inlet to said outlet along an x-axis of the Cartesian coordinate system, whereby said supports substantially preclude the airflow from exiting said channel along a trajectory defined by the y-axis of the Cartesian coordinate system.   
     
     
         24 . The spacer of  claim 23 , wherein said at least one airflow channel comprises a plurality of airflow channels. 
     
     
         25 . The spacer of  claim 22 , wherein said first surface material forming said substantially planar first surface of the spacer has a thermal conductivity of at least 3 W/m·K, and wherein said second surface material forming said substantially planar second surface of the spacer has a thermal conductivity of at least 3 W/m·K. 
     
     
         26 . The spacer of  claim 22 , wherein said first surface material forming said substantially planar first surface of the spacer has a thermal conductivity of at least 5 W/m·K, and wherein said second surface material forming said substantially planar second surface of the spacer has a thermal conductivity of at least 5 W/m·K. 
     
     
         27 . The spacer of  claim 22 , wherein said first surface material forming said substantially planar first surface of the spacer has a thermal conductivity of at least 10 W/m·K, and wherein said second surface material forming said substantially planar second surface of the spacer has a thermal conductivity of at least 10 W/m·K. 
     
     
         28 . The spacer of  claim 23 , wherein said spacer outer perimeter substantially defines a rectangle measuring about 40 inches by about 48 inches. 
     
     
         29 . The spacer of  claim 23 , wherein said spacer outer perimeter substantially defines a rectangle measuring about 42 inches by about 48 inches. 
     
     
         30 . The spacer of  claim 23 , wherein said spacer outer perimeter substantially defines a rectangle measuring about 41 inches by about 48 inches. 
     
     
         31 . The spacer of  claim 23 , wherein said spacer defines a load capacity for the quantity of product of about 1800 pounds. 
     
     
         32 . The spacer of  claim 23 , wherein said spacer defines a load capacity for the quantity of product of about 3600 pounds. 
     
     
         33 . The spacer of  claim 23 , wherein said first surface includes a plurality of perforations, said perforations are arranged such that at least one area of continuous surface free of said perforations and sized to receive a suction gripping device is provided on said first surface, wherein said at least one area of continuous surface free of said perforations and sized to receive a suction gripping device comprises an area of 4 sq. in. 
     
     
         34 . The spacer of  claim 23 , wherein said first surface and said second surface are both formed of an aluminum material. 
     
     
         35 . The spacer of  claim 23 , wherein said first surface and said second surface are both formed of a polymer. 
     
     
         36 . The spacer of  claim 23 , wherein said first surface comprises a first surface of a first 14 gauge aluminum plate and said second surface comprises a first surface of a second 14 gauge aluminum plate. 
     
     
         37 . The spacer of  claim 18 , wherein said first surface and said second surface are both formed of a 304 stainless steel material. 
     
     
         38 . The spacer of  claim 23 , wherein said first surface and said second surface are both formed of a mild steel. 
     
     
         39 . The spacer of  claim 23 , wherein said supports are spaced from each by other by about 4-6 inches measured along the y-axis of the Cartesian coordinate system, and wherein said supports extend along a trajectory defined by the z-axis to a height of about 0.25 to 3 in. 
     
     
         40 . The spacer of  claim 23 , wherein said spacer further comprises a lip extending from said spacer outer perimeter. 
     
     
         41 . A method of maintaining a quantity of a product at a desired temperature, comprising:
 preparing a pallet assembly by stacking a plurality of cases and a plurality of spacers on a pallet so that the plurality of cases are separated from each other along a z-axis of a Cartesian coordinate system by the spacers, the spacers comprising:
 a substantially planar first surface extending in an x-y plane of the Cartesian coordinate system, said planar first surface formed of a first surface material, said planar first surface defining a spacer outer perimeter of a size and shape about congruent to the outer perimeter of the pallet; 
 a substantially planar second surface formed of a second surface material; and 
 a plurality of supports extending between said first surface and said second surface along a trajectory having a directional component along a z-axis of the Cartesian coordinate system, whereby each of said plurality of supports space said first surface from said second surface, said first surface, said second surface and said supports defining at least one airflow channel, each of said plurality of airflow channels spanning a pair of opposing sides of at least one of said plurality of spacers, wherein one of said pair of opposing sides of said at least one spacer comprises an airflow inlet and the other of said pair of opposing sides of said at least one spacer comprises an airflow outlet, whereby an airflow enters said at least one airflow channel at said airflow inlet, traverses said channel and exits said channel at said airflow outlet to define an airflow trajectory from said inlet to said outlet along an x-axis of the Cartesian coordinate system, whereby said support substantially precludes the airflow from exiting said channel along a trajectory defined by the y-axis of the Cartesian coordinate system; 
   directing a thermally conditioned airflow through the at least one airflow channel of the spacers to adjust the temperature of the product contained in the plurality of cases to the desired temperature.   
     
     
         42 . The method of  claim 41 , wherein said at least one airflow channel comprises a plurality of airflow channels. 
     
     
         43 . The spacer of  claim 41 , wherein said first surface and said second surface are both coated with polytetrafluorethylene. 
     
     
         44 . The method of  claim 41 , wherein said first surface material forming said substantially planar first surface of the spacers has a thermal conductivity of at least 3 W/m·K, and wherein said second surface material forming said substantially planar second surface of the spacers has a thermal conductivity of at least 3 W/m·K. 
     
     
         45 . The method of  claim 41 , wherein said first surface material forming said substantially planar first surface of the spacers has a thermal conductivity of at least 5 W/m·K, and wherein said second surface material forming said substantially planar second surface of the spacers has a thermal conductivity of at least 5 W/m·K. 
     
     
         46 . The method of  claim 41 , wherein said first surface material forming said substantially planar first surface of the spacers has a thermal conductivity of at least 10 W/m·K, and wherein said second surface material forming said substantially planar second surface of the spacers has a thermal conductivity of at least 10 W/m·K. 
     
     
         47 . The method of  claim 41 , wherein said step of preparing a pallet assembly comprises the step of preparing a plurality of pallet assemblies. 
     
     
         48 . The method of  claim 47 , further comprising the steps of:
 positioning each of said plurality of pallet assemblies on one of a plurality of racks in a storage warehouse space, each of the plurality of racks positioned adjacent to an aisle, whereby a forklift can access each of the plurality of pallet assemblies.   
     
     
         49 . The method of  claim 47 , wherein said step of directing a thermally conditioned airflow through the at least one airflow channel of the spacers to adjust the temperature of the product contained in the plurality of cases positioned on either side of the plurality of spacers to the desired temperature comprises the steps of:
 positioning each of the plurality of pallet assemblies in fluid communication with an air intake opening defined by one of a plurality of racks occupying a storage warehouse space;   actuating at least one fan in fluid communication with a airflow chamber, the airflow chamber in fluid communication with the air intake opening, whereby the step of actuating the fan creates a circulation of ambient air flowing through the at least one airflow channel of each of the at least one spacer and thereafter to the air intake opening, and the airflow chamber and back to the warehouse space.   
     
     
         50 . The method of  claim 41 , wherein said spacer outer perimeter defines a rectangle measuring about 40 inches by about 48 inches. 
     
     
         51 . The method of  claim 41 , wherein said spacer outer perimeter defines a rectangle measuring about 42 inches by about 48 inches. 
     
     
         52 . The method of  claim 41 , wherein said spacer outer perimeter defines a rectangle measuring about 41 inches by about 48 inches. 
     
     
         53 . The method of  claim 41 , wherein said spacer defines a load capacity for the quantity of product of about 1800 pounds. 
     
     
         54 . The method of  claim 41 , wherein said spacer defines a load capacity for the quantity of product of about 3600 pounds. 
     
     
         55 . The method of  claim 41 , wherein said first surface includes a plurality of perforations, said perforations are arranged such that at least one area of continuous surface free of said perforations and sized to receive a suction gripping device is provided on said first surface, wherein said at least one area of continuous surface free of said perforations and sized to receive a suction gripping device comprises an area of 4 sq. in. 
     
     
         56 . The method of  claim 41 , wherein said first surface and said second surface are both formed of a polymer. 
     
     
         57 . The method of  claim 41 , wherein said first surface and said second surface are both formed of an aluminum material. 
     
     
         58 . The method of  claim 41 , wherein said first surface comprises a first surface of a first 14 gauge aluminum plate and said second surface comprises a first surface of a second 14 gauge aluminum plate. 
     
     
         59 . The method of  claim 41 , wherein said first surface and said second surface are both formed of a 304 stainless steel material. 
     
     
         60 . The method of  claim 41 , wherein said first surface and said second surface are both formed of a mild steel. 
     
     
         61 . The method of  claim 41 , wherein said supports are spaced from each by other by about 4-6 inches measured along the y-axis of the Cartesian coordinate system, and wherein said supports extend along a trajectory defined by the z-axis at a height of about 0.25 to 3 in. 
     
     
         62 . The method of  claim 41 , wherein said spacer further comprises a lip extending from said spacer outer perimeter.