The present subject matter relates generally to refrigerator appliances, and more particularly to ice making assemblies for refrigerator appliances.
Refrigerator appliances generally include a cabinet that defines one or more chilled chambers for receipt of food articles for storage. Typically, one or more doors are rotatably hinged to the cabinet to permit selective access to food items stored in the chilled chamber. Further, refrigerator appliances commonly include ice making assemblies mounted within an icebox on one of the doors or in a freezer compartment. The ice is stored in a storage bin and is accessible from within the freezer chamber or may be discharged through a dispenser recess defined on a front of the refrigerator door.
However, certain conventional ice making assemblies are positioned within an icebox that needs to be maintained at a low temperature to form ice from water poured in the ice mold. These low temperatures are often maintained by receiving a flow of air from a chilled chamber of the refrigerator appliance. However, blockages or restrictions may limit the amount of cool air that passes into the icebox, thereby resulting in higher icebox temperatures, more temperature gradients or variability, and generally poor ice making efficiency. For example, if a user overloads the chilled chamber, positions objects in the flow path of the cool air, or otherwise obstructs the flow, the formation of ice may take much longer or may not be possible at all.
Accordingly, a refrigerator appliance with features for improved ice formation would be desirable. More particularly, an ice making assembly for a refrigerator appliance and a method of operating the same to efficiently form ice would be particularly beneficial.
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.
In one exemplary embodiment, a refrigerator appliance defining a vertical direction, a lateral direction, and a transverse direction is provided. The refrigerator appliance comprises a cabinet defining a chilled chamber, a door being rotatably mounted to the cabinet to provide selective access to the chilled chamber, an ice making assembly comprising an ice mold, a mold temperature sensor, and a water supply spout, and a controller in operative communication with the mold temperature sensor. The controller is configured to fill the ice mold with water using the water supply spout, monitor an ice mold temperature using the mold temperature sensor, determine a mold cooling metric using the ice mold temperature, determine that the mold cooling metric falls below a predetermined threshold rate or is outside a target range, and implement a responsive action in response to determining that the mold cooling metric falls below the predetermined threshold rate or is outside the target range.
In another exemplary embodiment, a method of operating an ice making assembly of a refrigerator appliance is provided. The ice making assembly includes an ice mold, a mold temperature sensor, and a water supply spout. The method includes filling the ice mold with water using the water supply spout, monitoring an ice mold temperature using the mold temperature sensor, determining a mold cooling metric using the ice mold temperature, determining that the mold cooling metric falls below a predetermined threshold rate or is outside a target range, and implementing a responsive action in response to determining that the mold cooling metric falls below the predetermined threshold rate or is outside the target range.
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.
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.
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.
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.
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 second side 110 of housing 102 and a freezer chamber 124 arranged at or adjacent first side 108 of housing 102. As such, refrigerator appliance 100 is generally referred to as a side-by-side 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 bottom mount 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.
A refrigerator door 128 is rotatably hinged to an edge of housing 102 for selectively accessing fresh food chamber 122. In addition, a freezer door 130 is rotatably hinged to an edge of housing 102 for selectively accessing freezer chamber 124. Refrigerator door 128 and freezer door 130 are shown in the closed configuration in
Referring now generally to
Dispensing assembly 140 and its various components may be positioned at least in part within a dispenser recess 142 defined on freezer door 130. 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 freezer door 130. 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, as shown in
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 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 generally to
However, it should be appreciated that ice making assembly 200 is described herein only for the purpose of explaining aspects of the present subject matter. Variations and modifications may be made to ice making assembly 200 while remaining within the scope of the present subject matter. For example, ice making assembly 200 could instead be positioned within fresh food chamber 122 of refrigerator appliance 100 and may have any other suitable configuration.
As explained briefly above, certain conventional refrigerator appliances rely on the flow of the chilled air into an icebox in order to lower the ice mold temperature to facilitate ice formation. For example, referring now briefly to
According to the illustrated embodiment, icebox 150 is mounted to freezer door 130 and defines ice making chamber 154. Ice making assembly 200 is generally positioned within ice making chamber 154 and includes ice mold 204 and a water supply spout 202 for selectively adding water into ice mold 204 to facilitate ice formation. In addition, in order to reduce the temperature within ice making chamber 154 to a temperature sufficient to form ice, refrigerator appliance 100 may further include a sealed system 210 for generating a flow of chilled air (e.g., identified generally herein by reference numeral 212). For example, as would be understood by one having ordinary skill in the art, sealed system 210 may include a compressor, a condenser, a throttling device, and an evaporator. In addition, an air circulation fan 214 may be configured for circulating the flow of chilled air 212, e.g., through the evaporator of sealed system 210, throughout freezer chamber 124, and into ice making chamber 154.
According to the illustrated embodiment, sealed system 210 and air circulation fan 214 are positioned within a rear cooling duct 216. Rear cooling duct 216 may include an intake 218 positioned proximate a bottom of freezer chamber 124 and a discharge 220 proximate a top of freezer chamber 124. Accordingly, during normal operation, air circulation fan 214 draws in air from the bottom of freezer chamber 124 through intake 218 and discharges the flow of chilled air 212 out of discharge 220 at a top wall of freezer chamber 124.
Notably, the flow of chilled air 212 may have a tendency to cling to the top wall of freezer chamber 124 such that is directed through an intake 222 of icebox 150 at a very low temperature. The flow of chilled air 212 may cool ice making chamber 154 before exiting discharge 224 of icebox 150. The flow of chilled air 212 may then circulate within freezer chamber 124 before being recirculated through rear cooling duct 216 via intake 218, where the air may be recirculated.
Notably, as explained briefly above, a poor loading pattern within the chilled chamber may affect airflow to the door mounted icebox 150, resulting in higher temperatures within ice making chamber 154 that may reduce the efficiency of the ice making process. For example, as shown in
Accordingly, aspects of the present subject matter are directed to systems and methods for detecting poor airflow patterns or unsuitably high temperatures within icebox 150, along with corrective actions for addressing these issues and ensuring high-quality ice. For example, ice making assembly 200 may further include a mold temperature sensor 240 that is generally configured for monitoring a temperature of ice mold 204. As explained in more detail below, the measured ice mold temperature may be used to predict the efficiency of the ice formation process and the quality of ice being formed, and this information may be used to adjust the operation of refrigerator appliance 100 or ice making assembly 200.
As used herein, “temperature sensor” or the equivalent is intended to refer to any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, temperature sensor 240 may each be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, a semiconductor-based integrated circuit temperature sensor, etc. In addition, temperature sensor 240 may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and/or indicative of the temperature being measured. Although exemplary positioning of temperature sensors is described herein, it should be appreciated that refrigerator appliance 100 may include any other suitable number, type, and position of temperature and/or other sensors according to alternative embodiments.
Now that the construction of refrigerator appliance 100 and the configuration of controller 164 according to exemplary embodiments have been presented, an exemplary method 300 of operating a refrigerator appliance will be described. Although the discussion below refers to the exemplary method 300 of operating ice making assembly 200 or refrigerator appliance 100, one skilled in the art will appreciate that the exemplary method 300 is applicable to the operation of a variety of other ice making appliances. In exemplary embodiments, the various method steps as disclosed herein may be performed by controller 164 or a separate, dedicated controller.
Referring now to
Step 320 may include monitoring an ice mold temperature of the ice mold using a mold temperature sensor. In this regard, temperature sensor 240 may be used to monitor the temperature of ice mold 204. This ice mold temperature may be used to predict the quality of ice or target harvest times for the ice. For example, an exemplary mold temperature profile is illustrated in
According to example embodiments, the ice may be harvested after a harvest count is reached, the harvest count being a function both of mold temperature and time. In this regard, as used herein, the terms “harvest count” and the like are generally intended to refer to quantitative measures that determine when ice should be harvested. For example, the harvest count may be an integral of the ice mold temperature relative to a predetermined temperature over time. In this regard, as shown in
In
Step 330 generally includes determining a mold cooling rate or a “mold cooling metric” using the ice mold temperature. As used herein, the “mold cooling metric” may be a mold cooling rate (e.g., temperature change over period of time), a time-based metric for when the mold temperature reaches certain thresholds (e.g., minimum/maximum temperatures), or any other suitable metric that represents the relationship between the mold temperature as a function of time. For example, the mold cooling rate may be calculated at any time after water is added to ice mold 204 (e.g., after about 40 seconds). According to example embodiments, the mold cooling rate is determined immediately after adding water to the ice mold 204. In general, the mold cooling rate may be used to determine that there are issues with airflow and the cooling ability of ice making assembly 200. In addition, the mold cooling rate may be used to adjust the harvest count threshold or harvest time of ice within ice mold 204.
In this regard, if sealed system 210 is operating properly and the loading of objects 230 within freezer chamber 124 does not overly restrict airflow, the mold cooling rate may be such that the harvest count threshold is the harvest count illustrated in solid thin dotted vertical lines in
Step 350 may generally include implementing a responsive action in response to determining that the mold cooling rate falls below the predetermined threshold rate. In this regard, when step 340 results in a determination that the ice mold 204 is not being cooled quickly enough, method 300 may include adjusting the ice making process to compensate. Example responsive actions are provided below, but it should be appreciated that other adjustments may be made while remaining within the scope of the present subject matter. In addition, it should be appreciated that method 300 may include subsequently determining that the mold cooling rate has returned above the predetermined threshold rate and reversing the responsive actions, i.e., returning to normal operation.
According to an example embodiment, implementing the responsive action may include adjusting the target harvest count or the harvest count threshold at which ice should be harvested. For example, method 300 may include determining a harvest count threshold based at least in part on the mold cooling rate, e.g., with the harvest count threshold generally being inversely proportional to the mold cooling rate. Accordingly, by adjusting the harvest count threshold, the quality of the ice being formed may be ensured. Ice may be harvested when the measured harvest count exceeds the harvest count threshold. For example, according to the example of
According to still other embodiments, implementing the responsive action may include adjusting operating parameters of refrigerator appliance 100, e.g., such as adjusting operation of sealed system 212 or air circulation fan 214. In this regard, the speed of the sealed system compressor may be adjusted, the speed of air circulation fan 214 may be adjusted, or the operating duration of sealed system or some of its components may be modified. Other changes in operation of sealed system 210 may be used in an attempt to increase the mold cooling rate of ice mold 204.
According to still other embodiments, implementing the responsive action may include providing a user notification as to the airflow issue and/or requesting that the user rearrange objects 230 in freezer chamber 124. It should be appreciated that this user notification may be provided in any suitable manner and from any suitable device. For example, the user notification may be provided via control panel 160 or directly to a user's cell phone or mobile device (e.g., through an external network).
As explained above, aspects of the present subject matter are generally directed to a system for detecting a poor loading of a chamber of a refrigerator appliance. For example, the poor loading of a freezer may affect the airflow to the refrigerator door-mounted icemaker in a ductless airflow system. The occurrence of the poor loading of freezer may be determined by recording the time-temperature characteristics of the icemaker mold. For this, the change in temperature of the icemaker mold may be recorded for a period of time following the water-filling of the mold. If the change in temperature is below a threshold, the poor loading of the freezer is confirmed. Once the poor loading of the freezer is confirmed, the user may be notified and also the harvest count may be adjusted in accordance with a poor air-flow level to ensure that the quality of ice doesn't get degraded. Additionally, a fan algorithm may increase the air circulation (by increasing fan speed or by increasing the run time) inside the freezer to prevent warm spots.
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.