ICE MAKER APPLIANCE FROST MANAGEMENT

FIELD OF THE INVENTION

The present subject matter relates generally to ice maker appliances, and in particular to systems and methods for managing frost in such appliances.

BACKGROUND OF THE INVENTION

Certain refrigerator appliances include an ice maker. An ice maker appliance may also be a stand-alone appliance designed for use in commercial and/or residential settings. To produce ice, liquid water is directed to the ice maker and frozen. For example, certain ice makers include a mold body for receiving liquid water. In some systems, a working fluid is used to directly cool the mold body, e.g., by conductive heat transfer as opposed to cooling the air around the mold body, to form ice. After ice is formed in the mold body, it may be harvested from the mold body and stored within an ice bin or bucket within the refrigerator appliance.

Such direct cooling of the mold body provides more effective cooling of the mold body, e.g., as compared to indirect cooling via the air around the mold body. For example, this more effective cooling provides faster ice formation. The high cooling capacity of such systems, however, may also lead to frost formation and accumulation on the mold body. The mold body may be the coldest part in the ice box, thus leading to significant buildup of frost on and around the mold body, which may interfere with the operation of the ice maker.

Accordingly, an ice maker with features for effectively cooling the mold body while also managing, e.g., preventing or reducing, frost accumulation thereon would be desirable.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

According to an exemplary embodiment, a refrigerator appliance is provided. The refrigerator appliance includes a cabinet with a chilled compartment defined in the cabinet. The refrigerator appliance also include an ice box with an ice making assembly positioned in the ice box. The ice making assembly includes a mold body and a frost collector. The ice making assembly also includes a working fluid loop. The working fluid loop is in conductive thermal communication with the mold body and with the frost collector.

According to another exemplary embodiment, an ice maker appliance is provided. The ice maker appliance includes an ice box with a mold body and a frost collector both positioned in the ice box. The ice maker appliance also includes a working fluid loop. The working fluid loop is in conductive thermal communication with the mold body and with the frost collector.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a perspective view of a refrigerator appliance according to an exemplary embodiment of the present subject matter.

FIG. 2 provides a perspective view of the exemplary refrigerator appliance of FIG. 1, with the doors of the fresh food chamber shown in an open position.

FIG. 3 provides an interior perspective view of a dispenser door of the exemplary refrigerator appliance of FIG. 1.

FIG. 4 provides an interior elevation view of the door of FIG. 3 with an access door of the door shown in an open position.

FIG. 5 provides a schematic illustration of an exemplary ice maker in accordance with one or more embodiments of the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

As used herein, terms of approximation, such as “generally,” or “about” include values within ten percent greater or less than the stated value. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction. For example, “generally vertical” includes directions within ten degrees of vertical in any direction, e.g., clockwise or counterclockwise. As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.

FIG. 1 provides a perspective view of a refrigerator appliance 100 according to an exemplary embodiment of the present subject matter. Refrigerator appliance 100 includes a cabinet or housing 102 that extends between a top 104 and a bottom 106 along a vertical direction V, between a first side 108 and a second side 110 along a lateral direction L, and between a front side 112 and a rear side 114 along a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular to one another.

Housing 102 defines chilled chambers for receipt of food items for storage. In particular, housing 102 defines fresh food chamber 122 positioned at or adjacent top 104 of housing 102 and a freezer chamber 124 arranged at or adjacent bottom 106 of housing 102. As such, refrigerator appliance 100 is generally referred to as a bottom mount refrigerator. It is recognized, however, that the benefits of the present disclosure apply to other types and styles of refrigerator appliances such as, e.g., a top mount refrigerator appliance, a side-by-side style refrigerator appliance, or a single door refrigerator appliance. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular refrigerator chamber configuration.

Refrigerator doors 128 are rotatably hinged to an edge of housing 102 for selectively accessing fresh food chamber 122. In addition, a freezer door 130 is arranged below refrigerator doors 128 for selectively accessing freezer chamber 124. Freezer door 130 is coupled to a freezer drawer (not shown) slidably mounted within freezer chamber 124. Refrigerator doors 128 and freezer door 130 are shown in the closed configuration in FIG. 1. One skilled in the art will appreciate that other chamber and door configurations are possible and within the scope of the present invention.

FIG. 2 provides a perspective view of refrigerator appliance 100 shown with refrigerator doors 128 in the open position. As shown in FIG. 2, various storage components are mounted within fresh food chamber 122 to facilitate storage of food items therein as will be understood by those skilled in the art. In particular, the storage components may include bins 134 and shelves 136. Each of these storage components are configured for receipt of food items (e.g., beverages and/or solid food items, etc.) and may assist with organizing such food items. As illustrated, bins 134 may be mounted on refrigerator doors 128 or may slide into a receiving space in fresh food chamber 122. It should be appreciated that the illustrated storage components are used only for the purpose of explanation and that other storage components may be used and may have different sizes, shapes, and configurations.

Referring now generally to FIG. 1, a dispensing assembly 140 will be described according to exemplary embodiments of the present subject matter. Dispensing assembly 140 is generally configured for dispensing liquid water and/or ice. Although an exemplary dispensing assembly 140 is illustrated and described herein, it should be appreciated that variations and modifications may be made to dispensing assembly 140 while remaining within the present subject matter.

Dispensing assembly 140 and its various components may be positioned at least in part within a dispenser recess 142 defined on one of refrigerator doors 128. In this regard, dispenser recess 142 is defined on a front side 112 of refrigerator appliance 100 such that a user may operate dispensing assembly 140 without opening refrigerator door 128. In addition, dispenser recess 142 is positioned at a predetermined elevation convenient for a user to access ice and enabling the user to access ice without the need to bend-over. In the exemplary embodiment, dispenser recess 142 is positioned at a level that approximates the chest level of a user.

Dispensing assembly 140 includes an ice dispenser 144 including a discharging outlet 146 for discharging ice from dispensing assembly 140. An actuating mechanism 148, shown as a paddle, is mounted below discharging outlet 146 for operating ice or water dispenser 144. In alternative exemplary embodiments, any suitable actuating mechanism may be used to operate ice dispenser 144. For example, ice dispenser 144 can include a sensor (such as an ultrasonic sensor) or a button rather than the paddle. Discharging outlet 146 and actuating mechanism 148 are an external part of ice dispenser 144 and are mounted in dispenser recess 142.

By contrast, inside refrigerator appliance 100, refrigerator door 128 may define an icebox 150 (FIGS. 2 through 4) housing an ice making assembly which includes a mold body 200 and an ice storage bin 202 that are configured to supply ice to dispenser recess 142. In this regard, for example, icebox 150 may define an ice making chamber 154 for housing an ice making assembly, a storage mechanism, and a dispensing mechanism.

A control panel 160 is provided for controlling the mode of operation. For example, control panel 160 includes one or more selector inputs 162, such as knobs, buttons, touchscreen interfaces, etc., such as a water dispensing button and an ice-dispensing button, for selecting a desired mode of operation such as crushed or non-crushed ice. In addition, inputs 162 may be used to specify a fill volume or method of operating dispensing assembly 140. In this regard, inputs 162 may be in communication with a processing device or controller 164. Signals generated in controller 164 operate refrigerator appliance 100 and dispensing assembly 140 in response to selector inputs 162. Additionally, a display 166, such as an indicator light or a screen, may be provided on control panel 160. Display 166 may be in communication with controller 164, and may display information in response to signals from controller 164.

As used herein, “processing device” or “controller” may refer to one or more microprocessors or semiconductor devices and is not restricted necessarily to a single element. The processing device can be programmed to operate refrigerator appliance 100 and dispensing assembly 140. The processing device may include, or be associated with, one or more memory elements (e.g., non-transitory storage media). In some such embodiments, the memory elements include electrically erasable, programmable read only memory (EEPROM). Generally, the memory elements can store information accessible to the processing device, including instructions that can be executed by processing device. Optionally, the instructions can be software or any set of instructions and/or data that when executed by the processing device, cause the processing device to perform operations.

Referring now to FIGS. 3 and 4, FIG. 3 provides an interior perspective view of one of the refrigerator doors 128 and FIG. 4 provides an interior elevation view of the door 128 with an access door 170 shown in an open position. Refrigerator appliance 100 includes a sub-compartment 150 defined on refrigerator door 128. As mentioned above, the sub-compartment 150 may be referred to as an “icebox.” In the illustrated exemplary embodiment, icebox 150 extends into fresh food chamber 122 when refrigerator door 128 is in the closed position. As shown in FIG. 4, the mold body 200 may be positioned within the icebox 150. The mold body 200 is generally configured for freezing the water to form ice, e.g., ice pieces such as ice cubes, which may be stored in storage bin 202 and dispensed through discharging outlet 146 by dispensing assembly 140. For example, the mold body 200 may include one or more mold cavities defined therein, and liquid water may be directed into the mold cavity or cavities of the mold body 200 and the water may then be retained therein at a temperature at or below the freezing point of water to form an ice piece or ice pieces. FIG. 4 illustrates the mold body 200 with an ice storage bin 202 positioned below the mold body 200 for receiving ice pieces from the mold body 200, e.g., for receiving the ice after the ice is ejected from the mold body 200. As those of ordinary skill in the art will recognize, ice from the mold body 200 is collected and stored in the ice storage bin 202 and supplied to dispenser 144 (FIG. 1) from the ice storage bin 202 in icebox 150 on a back side of refrigerator door 128. Chilled air from a sealed system (not shown) of refrigerator appliance 100 may be directed into or onto components within the icebox 150, e.g., mold body 200 and/or ice storage bin 202.

As mentioned above, the present disclosure may also be applied to other types and styles of refrigerator appliances such as, e.g., a top mount refrigerator appliance, a side-by-side style refrigerator appliance or a standalone ice maker appliance. Variations and modifications may be made to ice making assembly while remaining within the scope of the present subject matter. Accordingly, the description herein of the icebox 150 on the door 128 of the fresh food chamber 122 is by way of example only. In other example embodiments, the ice making assembly may be positioned in the freezer chamber 124, e.g., of the illustrated bottom-mount refrigerator, of a side by side refrigerator, of a top-mount refrigerator, or any other suitable refrigerator appliance. As another example, the ice making assembly may also be provided in a standalone ice maker appliance. As used herein, the term “standalone ice maker appliance” refers to an appliance of which the sole or primary operation is generating or producing ice, e.g., without any additional or other chilled chambers other than the icebox, whereas the more general term “ice maker appliance” includes such appliances as well as appliances with diverse capabilities in addition to making ice, such as a refrigerator appliance equipped with an ice maker, among other possible examples.

As mentioned above, an access door 170 may be hinged to the inside of the refrigerator door 128. Access door 170 permits selective access to icebox 150. Any manner of suitable latch 172 may be configured with icebox 150 to maintain access door 170 in a closed position. As an example, latch 172 may be actuated by a consumer in order to open access door 170 for providing access into icebox 150. Access door 170 can also assist with insulating icebox 150, e.g., by thermally isolating or insulating icebox 150 from fresh food chamber 122.

As illustrated in FIG. 5, the ice making assembly employs a direct cooling system, e.g., whereby the mold body 200 is cooled by conductive heat transfer to a working fluid loop 238 that is in direct physical contact with, e.g., touching, the mold body 200. The exemplary ice making assembly illustrated in FIG. 5 generally includes a mold body 200 with one or more mold cavities defined therein for receiving liquid water and retaining at least a portion of the liquid water as the liquid water freezes to form ice, e.g., as described above. A working fluid may be circulated through the sealed working fluid loop 238 (comprising lines 214, 218, and 222), as further described below. The working fluid may be a refrigerant or coolant or other similar fluid. For example, the working fluid may be propane, isobutane, ammonia, ethylene glycol, propylene glycol, or other similar fluid, including combinations thereof. The working fluid may be provided in any suitable concentration, such as a mixture of any of the foregoing example fluids with water. A portion 216 of the working fluid loop 238 may be connected to or be situated in close proximity to a mold body 200 of ice making assembly, thereby effecting a direct (conductive) transfer of heat from mold body 200 to the sealed working fluid loop and/or the working fluid in the sealed working fluid loop, e.g., thereby chilling the mold body 200 such that liquid water in the mold body 200 freezes to form ice.

As mentioned, the mold body 200 may be directly, e.g., conductively, cooled by the working fluid loop 238. Thus, for example, the mold body 200 may be in contact with the working fluid loop 238, such as with a portion 216 of the working fluid loop 238, e.g., a portion of a connecting line 214 thereof which is downstream of a frost collector 250. In some embodiments, the mold body 200 may be in direct contact with the portion 216 of the working fluid loop 238 without any intervening space or structures therebetween. For example, in some embodiments, the portion 216 of the working fluid loop 238 may extend through and within a portion of the mold body 200, such as the portion 216 may be fully embedded within the mold body 200 whereby the portion 216 is surrounded by the mold body in all directions, or the portion 216 may be partially embedded within the mold body 200, e.g., the portion 216 may be received within a groove or recess formed in a side of the mold body 200, or the portion 216 may be outside of the mold body 200 and in direct contact with an external surface of the mold body 200.

The sealed working fluid loop 238 may include a working fluid pump 220 that is operable to urge the working fluid therethrough. For example, activating the working fluid pump 220 may cause the working fluid to circulate through the sealed working fluid loop 238, such as at a flow rate proportional to the operating speed of the working fluid pump 220. The working fluid pump 220 may supply the working fluid to a pressure line 222, which is connected to, e.g., coupled directly to, a first inlet 226 at a frost collector 250, which may be, e.g., a heat exchanger or a plate, as will be described in more detail below. The working fluid in the sealed working fluid loop 238 may travel through the frost collector from the first inlet 226 to a first outlet 228, e.g., the sealed working fluid loop 238 may include a portion which is fully or partially embedded in the frost collector 250 (such as fully embedded, e.g., as illustrated in FIG. 5), or which is outside of the frost collector 250 and in direct contact with an external surface of the frost collector, in a similar manner as described above with respect to the mold body 200. A connecting line 214 extends from the frost collector to the mold body 200, where a portion 216 of the working fluid loop 238 may be connected to the mold body 200 as described above. For example, in the embodiment illustrated in FIG. 5, the portion 216 may enter the mold body 200 at an inlet 230 of the mold body 200 and the portion 216 may extend to an outlet 232 of the mold body 200, where the working fluid loop 238 exits the mold body 200. Thus, the working fluid draws heat from the mold body 200, e.g., chills the mold body 200 such that liquid water in the one or more mold cavities of the mold body 200 may form ice, as the working fluid flows through the portion 216 of the working fluid loop 238.

From the mold body 200, e.g., downstream of the portion 216 in contact with the mold body 200, the working fluid in the sealed working fluid loop 238 returns to the working fluid pump 220 via a suction line 218.

In some embodiments, e.g., as illustrated in FIG. 5, the working fluid loop 238 may include one or more inlets, e.g., a first inlet 226 at the frost collector 250 and a second inlet 230 at the mold body 200, and a corresponding number of outlets, e.g., a first outlet 228 from the frost collector 250 and a second outlet 232 from the mold body 200.

The frost collector 250 may be upstream of the mold body 200 along the working fluid loop 238, e.g., the working fluid flowing through the working fluid loop 238 may first travel to the frost collector 250, whereupon the frost collector 250 is cooled and the working fluid in the working fluid loop 238 is warmed, and then the working fluid in the working fluid loop 238 may travel to the mold body 200, such that the working fluid is warmer when the working fluid reaches the mold body 200 than when the working fluid reaches the frost collector 250. Thus, the frost collector 250 may be colder than the mold body 200, such that any frost that does form in the icebox 150 will preferentially form at and on the frost collector 250 more than the mold body 200. Accordingly, the accumulation of frost, if any, which may occur within the icebox 150 is less likely to impede operations of the ice making assembly because the frost will form on the frost collector 250 rather than the mold body 200, e.g., will form on the frost collector 250 before or to a greater extent than the mold body 200.

The frost collector 250 generally comprises a material having a high thermal conductivity, such as a metal material, such as aluminum, zinc, copper, and/or other similar metal materials including alloys thereof. The frost collector 250 may be spaced apart from the mold body 200, such as by at least a distance sufficient to prevent or minimize accumulated frost bridging the space between the frost collector 250 and the bold body 200. As mentioned, the frost collector 250 may be a plate or may be a heat exchanger. For example, in embodiments where the frost collector 250 is a plate, the frost collector 250 may comprise a generally rectangular prism shape with each side of the frost collector 250 being generally flat. As another example, in embodiments where the frost collector 250 is a heat exchanger, the frost collector 250 may include a plurality of fins formed on at least one side of the frost collector 250 to provide increased surface area to volume of the frost collector 250, thereby increasing the rate of thermal transfer between the frost collector 250 and the air within the icebox 150. The structure and function of heat exchangers, such as fins thereof, are well understood by those of ordinary skill in the art and, as such, are not specifically illustrated or described in further detail herein for the sake of brevity and clarity. In some embodiments, a fan 224 may be included in close proximity to, such as in contact with, the frost collector 250. While the fan 224 may not necessarily be in contact with the frost collector 250, the fan 244 is positioned at least close enough to the frost collector 250 that, when the fan 244 is activated, the fan 244 may urge a flow of air across and/or around the frost collector 250. For example, in embodiments where the frost collector 250 is provided as a heat exchanger including fins, the fan 244 may urge the flow of air between, around, through, and/or across the fins of the frost collector 250. Such air flow urged by the fan 244 may be useful to decrease, e.g., cool down, the ambient temperature within the icebox 150.

The ice making assembly may further include a harvest heater 240 attached to or otherwise in close proximity to the mold body 200, such that the harvest heater 240 is operable to raise a temperature of the mold body 200 to promote the release of ice pieces from within the cavity or cavities, as is understood by those of skill in the art. The ice making assembly may also include a defrost heater 242 attached to or otherwise in close proximity to the frost collector 250 such that the defrost heater 242 is thermal communication with the frost collector. For example, the frost collector 250 may have a carrying capacity or carrying limit as to how much frost may be formed thereon, after which additional frost which forms in the icebox 150 (e.g., within the chamber 154 therein) may accumulate on other surfaces than the frost collector 250. Thus, the defrost heater 242 may be operable to remove frost from the frost collector when the defrost heater 242 is activated, and periodically removing such frost may restore the capacity of the frost collector 250 to carry or accumulate frost thereon, e.g., preferentially to other components of the ice making assembly such as the mold body 200.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

ICE MAKER APPLIANCE FROST MANAGEMENT

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