The invention relates generally to refrigerators. More particularly, but not exclusively, the invention relates to a refrigerator having a cooling system wherein an evaporator is defrosted using air from a compartment of the refrigerator having a temperature above freezing.
Bottom mount refrigerators include a freezer compartment on the bottom, with the fresh food or refrigerator compartment above the freezer compartment. One or more doors provide access to the fresh food compartment, and a separate door provides access to the freezer compartment. The freezer door or doors may be drawer-type doors that are pulled out, or they may be hingedly connected similar to the refrigerator compartment doors, such that they are rotated to provide access within.
The refrigerator and freezer compartments may be cooled using a single evaporator cooling system, in which the single evaporator cools air to be directed to the compartments to keep them at a predetermined temperature, or the refrigerator may include a dual evaporator system. Dual evaporator systems include two evaporators in the cooling cycle, with the separate evaporators dedicated to cooling air for a specific compartment (i.e., one evaporator for the refrigerator compartment, and one for the freezer compartment).
A cooled refrigerant is passed through the evaporator. The cold liquid-vapor mixture of refrigerant travels through the evaporator coil or tubes and is completely vaporized by cooling the warm air (from the space being refrigerated) being blown by a fan across the evaporator coil or tubes. However, because the refrigerant that passes through the coils of the evaporator is at a cold temperature, frost can form on the coils, especially when the cooling system is cooling a freezer compartment or other low temperature compartment. If too much frost forms on the coils, the evaporator will freeze up, and the cooling system will not properly cool the compartment(s) of the refrigerator.
Therefore, defrost systems are placed on or near the evaporators to aid in melting the frost off the coils, generally when the cooling system is not running (i.e., when the temperatures of the compartment(s) are at or below the set/predetermined temperatures). Most refrigerator evaporators use an electrical heater to defrost. The frost melts off the evaporator coils and drains to a pan in the machine compartment. The water in the pan evaporates into the air, which is routed to room air. The use of an electrical heater requires electricity to warm the heater, which can increase the cost of electricity required to run the refrigerator.
As the costs of energy increases, consumers have demanded low energy appliances to try to keep their bills at a minimum. Therefore, there is a need in the art for a low energy solution to defrost the evaporator coils in a refrigerator cooling system, which includes removing an electrical heater or warming component from the evaporator coils.
Therefore, it is a primary object, feature, and/or advantage of the present invention to provide an apparatus that overcomes the deficiencies in the art.
It is another object, feature, and/or advantage of the present invention to provide a low energy solution to defrost evaporator coils in a refrigerator cooling system.
It is yet another object, feature, and/or advantage of the present invention to provide a low energy defrost solution that includes using above-freezing air from the refrigerator compartment to defrost the evaporator coils.
It is still another object, feature, and/or advantage of the present invention to provide a low energy defrost solution that includes directing ambient air from outside the refrigerator to the evaporator to defrost the evaporator coils.
It is a further object, feature, and/or advantage of the present invention to provide a low energy defrost solution that can defrost coils on multiple evaporators.
It is still a further object, feature, and/or advantage of the present invention to provide a low energy defrost solution that combines air from the refrigerator compartment and ambient external air to defrost the coils on the one or more evaporators.
It is yet a further object, feature, and/or advantage of the present invention to provide a defrost solution for an evaporator of a refrigerator cooling system that aids in lowering the energy costs of a consumer.
These and/or other objects, features, and advantages of the present invention will be apparent to those skilled in the art. The present invention is not to be limited to or by these objects, features and advantages. No single embodiment need provide each and every object, feature, or advantage.
According to an aspect of the present invention, a refrigerator is provided. The refrigerator includes a refrigerator compartment and a freezer compartment. An evaporator is provided for cooling both the refrigerator and the freezer compartment. A defrost air loop is provided for directing refrigerator compartment air from the refrigerator compartment to the evaporator and back to the refrigerator compartment, wherein the refrigerator compartment air is configured to melt frost on the evaporator and cool, and wherein the cooled air is returned to the refrigerator compartment. An evaporator pan is operably connected to the evaporator and configured to store the melted frost of the evaporator.
According to another aspect of the present invention, a defrost air loop assembly for defrosting an evaporator of a cooling system is provided. The assembly includes a first compartment having a temperature above freezing; a second compartment having a temperature below freezing; a first air duct between the evaporator and the first compartment; and a return duct between the first compartment and the evaporator to direct above freezing air to the evaporator to defrost said evaporator.
According to yet another aspect of the present invention, a method of defrosting an evaporator of a cooling system of a refrigerator is provided. The method includes providing an air duct and a return duct between the evaporator and a first compartment of the refrigerator having a temperature above freezing; directing the above freezing temperature in the return duct to the evaporator; and redirecting the air from the evaporator through the air duct to the first compartment to aid in cooling the compartment.
The invention involves using refrigerator compartment air to melt frost on evaporator coils. The refrigerator compartment air is above freezing. Drawing forced air in a loop to the evaporator and back will melt the ice on the evaporator. It will also recapture the latent heat of fusion from the frost. The system will not waste energy through electrical heat. Melt water will be routed to the evaporator pan in the machine compartment. Alternatively, an air stream directly to and from the exterior of the product can be used for defrost, instead of using refrigerator compartment air.
It should also be appreciated that, while the figures show a bottom mount-style refrigerator 10, the present invention contemplates that any style of a refrigerator be included as part of the invention. The figures merely depict one example of a type of refrigerator that can be used with the present invention.
However, as the evaporator 26 receives the super cooled refrigerant, prolonged use of the evaporator 26 (i.e., prolonged running of the cooling system 24 to constantly cool the refrigerator 10) could result in the coils 27 of the evaporator 26 freezing up and having frost begin to grow thereon. The frost could eventually continue until the coils 27 of the evaporator 26 freeze up, which would not allow the refrigerant to pass through the evaporator 26. This would not allow the cooling system 24 to cool the compartments of the refrigerator 10, and therefore, defrosting of the evaporator 26 is required during periods when the refrigerator 10 does not need the cooling system 24 to run and cool the compartments therein.
Therefore,
The refrigerator 10 shown in
In addition, as the air is passed over the coils 27 of the evaporator 26, the air will give off heat to the frost to melt the frost. Thus, once the air has passed the evaporator 26, the air will have a lower temperature than before. The cooled air may then be directed in the cooling duct 42 and returned back to the refrigerator compartment 14 to aid in cooling said refrigerator compartment 14. Thus, the refrigerator compartment 14 is cooled without running the cooling system 24 of the refrigerator 10. To aid in the movement of the air in the direction shown as the arrow 36 in the cooling duct 42, a fan 46, which may be known as a cooling fan, may be turned on to aid in directing the air from the evaporator 26 back to the refrigerator compartment 14. It should be noted that the cooling fan 46 and the return fan 47 will require minimal energy, such that the energy usage of the fans will be less than the energy usage of an electrical heater, which has previously been used to defrost the evaporator 26. Furthermore, it should be contemplated that the use of the fans may not be required, and the air may flow through the duct system 40 without the need of the fans.
Furthermore, the duct system 40 may include refrigerator compartment baffles 38 at the location of the cooling duct 42 and return duct 44 being exposed to the refrigerator compartment 14. As noted above, the defrosting of the evaporator 26 is generally only done while the cooling system 24 is not running. Therefore, when the cooling system 24 is running, the defrost air loop 34 can be blocked to prevent the air from passing through the air loop. Therefore, the baffles 38 can block air from passing through the duct system 40. However, when the cooling system 24 is off, and the defrost operation is run, the baffles can be opened to move the air through the air loop 34. The baffles 38 may be controlled electrically as needed, using minimal energy to open and close the baffles 38, and the system may include one or a plurality of baffles as needed to best control the temperature of the refrigerator and the defrost system.
However, it should also be contemplated that the duct system 40 of the defrost air loop 34 may also utilize the standard cooling duct for the refrigerant compartment 14. For instance, when the refrigerator compartment 14 is being cooled by the cooling system 24, air will be generally directed from the refrigerator compartment 14 through the evaporator 26 and back into the refrigerator compartment 14. However, during the cooling process, the evaporator will be running, and thus the air from the refrigerator compartment will not stop frost forming on the coils 27 of the evaporator 26. The defrost cycle will generally only occur when the evaporator 26 in cooling 24 are in an off configuration (i.e., not passing refrigerant therethrough).
Likewise, the external defrost air loop 48 directs external air from adjacent the refrigerator 10 over and adjacent to the coils of the second evaporator 58 to melt any frost that has formed on the coils of the evaporator 58. The air is then directed or returned outside or externally of the refrigerator 10. For both defrost air loops 34, 48, the melted frost of the evaporators can be collected in an evaporator pan 56, where it is allowed to evaporate into the air.
Furthermore,
As shown, the low energy defrost systems of the present invention include many advantages. For example, the defrost systems of the air loops 34, 48 provide systems and methods for defrosting the evaporator coils of the refrigerator without the need for an electrical heater on or adjacent the evaporators. As noted previously, electrical heaters require more energy to operate the heaters, which then increases the energy usage of the refrigerator. Therefore, the use of the present invention provides a low energy or more energy efficient way of running a refrigerator. Thus, the less energy used, the lower the cost that will be passed to the consumer of the refrigerator. While the systems and methods of the present invention can include baffles and fans, which may be electrically run, the electricity or energy required to operate the baffles and fans will generally be much less than that required to operate an electrical heater. Therefore, embodiments including the use of the fans and baffles will still provide a more efficient and less energy-using refrigerator. Furthermore, when refrigerator compartment air is used to defrost the evaporator, the air is re-cooled by the melting of the frost on the evaporator. Thus, the re-cooled air is then redirected into the refrigerator compartment to aid in cooling said compartment. The air has been re-cooled without turning on the cooling system of the refrigerator, which additionally increases the efficiency and lessens the energy consumption of the refrigerator.
Once the temperatures for both the refrigerator compartment and freezer compartment are below the set or programmed temperatures, the defrost cycle 71 can be run by the refrigerator 10. For example, as shown in
While
The foregoing description has been presented for purposes of illustration and description. It is not intended to be an exhaustive list or limit the invention to precise forms disclosed. It is contemplated that other alternative processes and systems obvious to those skilled in the art are considered to be included in the invention. The description is merely examples of embodiments. For example, the present invention contemplates that instead of having only external or only refrigerator compartment air used to defrost the evaporators, the present invention contemplates that a combination of air from the refrigerator compartment and external air can be used. Furthermore, as discussed above, when refrigerator compartment air is used, an additional duct is not needed to direct the air. For example, the system could use existing ducts for cooling the refrigerator compartment in reverse to direct air from the refrigerator compartment to the evaporator to melt any frost formed on the evaporator. It is understood that any other modifications, substitutions, and/or additions may be made, which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of the stated objectives.
This application is a Continuation Application of U.S. application Ser. No. 14/662,271, filed Mar. 19, 2015, which is a continuation of U.S. application Ser. No. 13/656,801, filed on Oct. 22, 2012, now U.S. Pat. No. 8,997,507, the entire disclosures of which are expressly incorporated herein by reference in their entirety.
Number | Date | Country | |
---|---|---|---|
Parent | 14662271 | Mar 2015 | US |
Child | 15805493 | US | |
Parent | 13656801 | Oct 2012 | US |
Child | 14662271 | US |