Patent Application
20250230970
The present subject matter relates generally to refrigerator appliances, and more particularly to door-mounted icemakers 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.
It may be desirable to place craft icemakers on the freezer door for forming craft ice cubes, which are typically large cubes made by a conventional twist tray icemaker. Ideally, such an icemaker reliably produces high quality ice if the ambient temperature is maintained at a temperature elevated relative to the typical freezer compartment in which the icebox is located. Maintaining temperatures above this level may produce high-quality cubes with no cracks or surface bumps. In addition, these cubes may be easy to release from the icemaker mold. However, due to their positioning within the freezer compartment, door-mounted craft icemakers are typically maintained at too low a temperature, resulting in poor ice quality, poor harvest reliability, and consumer dissatisfaction. In addition, these compartments may prevent warm air from escaping, resulting in trapped humidity inside the compartment when water is added.
Accordingly, a refrigerator appliance with features for improved ice making would be desirable. More particularly, a refrigerator appliance with a door-mounted craft icemaker that is maintained at a temperature to produce high quality craft 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, including a cabinet defining a chilled chamber, a door being rotatably mounted to the cabinet to provide selective access to the chilled chamber, the door at least partially defining an icebox and comprising an outer door panel and an inner door panel spaced apart along the transverse direction to define a door gap that is filled with insulation, wherein a nominal door gap thickness is defined away from an icebox and an icebox door gap thickness is defined adjacent the icebox, the icebox door gap thickness being less than the nominal door gap thickness, and an insulated cover mounted to the door to at least partially define and thermally isolate the icebox from the chilled chamber.
In another exemplary embodiment, a refrigerator appliance defining a vertical direction, a lateral direction, and a transverse direction is provided, including a cabinet defining a chilled chamber, a door being rotatably mounted to the cabinet to provide selective access to the chilled chamber, the door at least partially defining an icebox, wherein a thickness of the door is reduced proximate the icebox, and an insulated cover mounted to the door to at least partially define and thermally isolate the icebox from the chilled chamber.
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.
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. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). The term “at least one of” in the context of, e.g., “at least one of A, B, and C” refers to only A, only B, only C, or any combination of A, B, and C. In addition, here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, 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, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.
The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, 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 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 120 positioned at or adjacent second side 110 of housing 102 and a freezer chamber 122 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 124 is rotatably hinged to an edge of housing 102 for selectively accessing fresh food chamber 120. In addition, a freezer door 126 is rotatably hinged to an edge of housing 102 for selectively accessing freezer chamber 122. Refrigerator door 124 and freezer door 126 are shown in the closed configuration in
A control panel 130 is provided for controlling the mode of operation. For example, control panel 130 includes one or more selector inputs 132, 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 132 may be used to specify a fill volume or method of operating dispensing assembly 150. In this regard, inputs 132 may be in communication with a processing device or controller 134. Signals generated in controller 134 operate refrigerator appliance 100 and dispensing assembly 150 in response to selector inputs 132. Additionally, a display 136, such as an indicator light or a screen, may be provided on control panel 130. Display 136 may be in communication with controller 134 and may display information in response to signals from controller 134.
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 150. 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
Dispensing assembly 150 and its various components may be positioned at least in part within a dispenser recess 152 defined on freezer door 126. In this regard, dispenser recess 152 is defined on a front side 112 of refrigerator appliance 100 such that a user may operate dispensing assembly 150 without opening freezer door 126. In addition, dispenser recess 152 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 152 is positioned at a level that approximates the chest level of a user.
Dispensing assembly 150 includes an ice dispenser 154 including a discharging outlet 156 for discharging ice from dispensing assembly 150. An actuating mechanism 158, shown as a paddle, is mounted below discharging outlet 156 for operating ice or water dispenser 154. In alternative exemplary embodiments, any suitable actuating mechanism may be used to operate ice dispenser 154. For example, ice dispenser 154 can include a sensor (such as an ultrasonic sensor) or a button rather than the paddle. Discharging outlet 156 and actuating mechanism 158 are an external part of ice dispenser 154 and are mounted in dispenser recess 152.
As shown in
In addition, according to an example embodiment of the present subject matter, freezer door 126 may also include a second icebox 162 that may house an icemaker 164 that operates independently of the icemaker in first icebox 160. For example, icemaker 164 may be a craft icemaker for forming “craft ice” that is commonly large, clear cubes or spheres of ice for alcoholic or non-alcoholic drinks. A storage bin 166 may be positioned below icemaker for storing formed ice. A user may access this craft ice by opening freezer door 126 and accessing storage bin 166 directly.
Notably, the formation of craft ice may generally be improved if the ice formation temperature is elevated relative to conventional freezer temperatures. For example, conventional freezer temperatures hover around 0° F., whereas desired temperature for forming craft ice of high quality may be between about 15° F. and 20° F. Accordingly, aspects of the present subject matter generally directed to features of icemaker 164 and second icebox 162 that facilitate increased icebox temperatures and improved ice formation.
Specifically, referring now also to
Specifically, referring to
Notably, the reduced door thickness proximate second icebox 162 may facilitate improved thermal transfer with the area outside of refrigerator appliance 100, but second icebox 162 may still be exposed to very cold air from within freezer chamber 122. Accordingly, refrigerator appliance 100 may further include an insulated cover 220 that is mounted to freezer door 126 to at least partially define and thermally isolate second icebox 162 from freezer chamber 122. Notably, conventional icebox covers are a single piece of hard plastic with no insulation, as the intention is to create massive volumes of ice without concern for their quality (contrary to the formation of craft ice). However, insulated cover 220 may be specially designed and configured for reducing the thermal transfer from freezer chamber 122 into second icebox 162.
In this regard, insulated cover 220 and freezer door 126 have geometries suitable to substantially contain or seal second icebox 162 from freezer chamber 122 along the top, front, back, and sides of second icebox 162. As shown, a bottom side of second icebox 162 may be open such that craft ice may be discharged from icemaker 164 where it may be contained within storage bin 166. As shown, in order to achieve such insulation of second icebox 162, insulated cover 220 may generally include a hard outer shell 222 that is filled or lined with an insulating material 224. The thickness of insulating material 224 may vary as needed for desired thermal transfer between freezer chamber 122 and second icebox 162. In this manner, by increasing the thermal communication between second icebox 162 and the outside and decreasing thermal communication between freezer chamber 122 and second icebox 162, second icebox 162 may be maintained at a desired temperature for forming craft ice (15° to 20° Fahrenheit) while freezer chamber 122 may be maintained at the target freezer temperature (0° Fahrenheit).
Notably, sealing off second icebox 162 in the manner described above may be desirable for maintaining suitable temperatures for forming craft ice. However, certain conditions may occur where warm, humid air inside second icebox 162 is unable to escape, e.g., when icemaker 164 is filled with water. If the humidity within second icebox 162 is unable to escape, frost may have a tendency to form on the inner walls of freezer door 126 and insulated cover 220. This frost may build up over time and affect the operation of the icemaker when 164 and the ice formation process.
Accordingly, aspects of the present subject matter are further directed to systems and methods for regulating humidity and temperatures within second icebox 162. In this regard, for example, a fan 230 may be positioned within second icebox 162 or may be placed in fluid communication with second icebox 162. Fan 230 may be periodically operated in order to circulate a flow of air (e.g., identified herein generally by reference numeral 232) throughout second icebox 162. For example, fan 230 may be positioned for intaking cold dry air from freezer chamber 122 which may help discharge the humidity and sublimate any formed frost within second icebox 162. In addition, one or more flow features (e.g., identified as louvers 234 in
According to still other embodiments, refrigerator appliance 100 may include a heating assembly 240 that is in thermal communication with second icebox 162 for selectively heating second icebox 162. For example, heating assembly 240 may include a plurality of resistive heaters 242 that are positioned within insulated cover 220 and freezer door 126. Heating assembly 240 may be selectively operated in order to melt any collected frost, to regulate the temperature within second icebox 162, etc.
Refrigerator appliance 100 may further include one or more temperature sensors 250 that are generally positioned for monitoring the temperatures of freezer chamber 122, second icebox 162, evaporator temperatures, etc. Specifically, according to the illustrated embodiment, temperature sensor 250 may be positioned within second icebox 162 for monitoring temperatures therein. Controller 134 may be in operative communication with temperature sensor 250 to measure temperatures, detect the presence of frost, etc.
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 250 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 250 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, humidity, and/or other sensors according to alternative embodiments.
Controller 134 may be programmed to determine when a defrost cycle is needed and selectively operated fan 230 to purge humid air from second icebox 162 and reduce the frost formation. In this regard, for example, it may be determined that a defrost cycle is needed based on elapsed time since a prior defrost cycle, an indication of frost buildup, or a number of icemaking cycles performed since the prior defrost cycle. According to still other embodiments, determining that the defrost cycle is needed may be based on a measured icebox temperature, a measured freezer temperature, and/or a measured freezer evaporator temperature. Similarly, controller 134 may be programmed to determine when frost has formed and may operate heating assembly 240 accordingly to adjust the temperature within second icebox 162. Controller 134 may also use heating assembly 240 to regulate temperature to the desired ice formation temperature.
As explained herein, aspects of the present subject matter are generally directed to a passive temperature control system for an icemaker in a door of a refrigerator appliance. For example, the icemaker may be located on a freezer door, and an insulated cover may be placed over the top of the icemaker, such that the space between the cover and inner door liner forms the ice-making compartment. The insulation in the exterior-facing wall of the freezer door may be thinned down to allow more heat transfer into the ice making compartment, and the insulated cover may be used to reduce heat transfer between the ice-making compartment and the surrounding freezer air.
According to still other aspects of the present subject matter, a refrigerator appliance with a defrost system for an ice-making compartment is provided. The defrost system may include a fan that is attached to the lower wall of the ice-making compartment, and the fan may be louvered or angled to pull dry cold air from the freezer compartment into the ice-making compartment, thereby purging any humid air inside the ice-making compartment to the freezer compartment. The fan may be allowed to run for an extended period of time to sublimate and remove frost from the inner walls of the ice-making compartment (effectively defrosting the ice-making compartment). In addition, a control may determine when to defrost based on harvest cycles or freezer ambient temperature and freezer evaporator temperatures.
Alternatively, heaters may be provided inside the insulation of the cover and inside the foam of the freezer door to help prevent frost formation.
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.
