Patent Application
20230304717
The present disclosure relates to a refrigeration appliance with a water fill tube, and more specifically, reducing ice formation within water fill tubes in an ice making system.
Household appliances, such as refrigerators and freezers, typically include water lines and fill tubes (hereinafter interchangeably referenced) for supplying water to various devices such as the ice making system. These water fill tubes are susceptible to freezing given the cold environment. Conventional water fill tubes are formed of plastic, which has generally insulative properties. For example, the thermal conductivity of high-density polyethylene (HDPE) is about 0.2 to 0.3 W/m-K in the temperature range of -15 to 40° C. Conventional refrigerators and freezers include a foil heater to transfer heat to the ice formed inside the water fill tube by using a heater wire placed between foil sheets and adhered to the surface of the tube or wrapping the heater wire around the tube covering the wire with an aluminum foil sheet with adhesive backing. However, because of the insulative properties of the water fill tube material, heat transfer to the ice within the water fill tube is limited. Furthermore, for portions of the water fill tube supplying an ice making system that are positioned within an ice making compartment, the heat transfer from the foil heater to the ice inside the water fill tube is further limited due to distance and heat loss between these portions and the foil heater.
According to one or more embodiments, a refrigeration appliance includes an appliance body defining a plurality of compartments, and an ice making system in a first compartment of the plurality of compartments with an ice making compartment disposed therein. The refrigeration appliance also includes a water fill tube extending from a second compartment of the plurality of compartments to the first compartment to supply water to the ice making compartment, the water fill tube having a body with an inner surface defining a cavity for flowing water and an outer surface. The body includes at least a portion with a thermally conductive filler dispersed in a polymer material. The refrigeration appliance also includes a heating device configured to supply heat to the water fill tube, where the thermally conductive filler conducts heat along and through a thickness of the body to melt ice and prevent ice build-up in the water fill tube.
In at least one embodiment, the thermally conductive filler may be aluminum, graphite, copper, zinc, glass fiber, or combinations thereof. Furthermore, the thermally conductive filler may be provided as flakes having an average volume of 5 to 75 mm3. In at least one embodiment, the polymer material may be high density polyethylene, cross-linked polyethylene, or polyethylene. In certain embodiments, the thermally conductive filler may increase a thermal conductivity of the portion of the water fill tube by half to 16 times of an unfilled polymer material. According to at least one embodiment, the water fill tube may include a first portion corresponding to a section of the water fill tube external to the ice making compartment, and a second portion corresponding to a section of the water fill tube within the ice making compartment, with at least the second portion including the thermally conductive filler dispersed in the polymer material. In at least one further embodiment, the heating device may be positioned to supply heat to the first portion. In some further embodiments, the second portion includes an end body with thermally conductive filler dispersed in the polymer material. In one or more embodiments, the thermally conductive filler may be loaded in the polymer material at 0.5 to 25% by weight.
According to one or more embodiments, a water fill tube for a refrigeration appliance, the water fill includes a body having an inner surface defining a cavity for flowing water, and an outer surface. The body includes a thermally conductive filler dispersed in a polymer material. The thermally conductive filler conducts heat from the outer surface such through and along the body to melt ice and prevent ice build-up in the cavity.
In at least one embodiment, the thermally conductive filler may be aluminum, graphite, copper, zinc, glass fiber, or combinations thereof. In certain embodiments, the thermally conductive filler may be provided as flakes having an average volume of 5 to 75 mm3. In one or more embodiments, the thermally conductive filler may be loaded in the polymer material at 0.5 to 25% by weight. In at least one embodiment, the thermally conductive filler may increase a thermal conductivity of the body by half to 16 times of an unfilled polymer material. According to at least one embodiment, the water fill tube may further comprise a heating device on a first portion of the body to supply heat to the portion, wherein the thermally conductive filler may be included in a second portion of the body, different from the first portion. In one or more embodiments, the polymer material may be high density polyethylene, cross-linked polyethylene, or polyethylene.
According to one or more embodiments, a water fill tube for a refrigeration appliance includes a first body having a first inner surface defining a first inner cavity for flowing water, and a first outer surface, and a second body positioned on an end of the first body. The second body defines a second inner cavity for flowing water and a second outer surface, and is formed of a polymer material with a thermally conductive filler dispersed therein. The water fill tube further includes a heating device positioned on at least a portion of the first outer surface of the first body. The heating device heats the portion of the first outer surface of the first body such that heat conducts to the second body and the thermally conductive filler conducts heat from the second outer surface to the second inner cavity of the second body to melt ice and prevent ice build-up in the second inner cavity.
In at least one embodiment, the thermally conductive filler may be aluminum, graphite, copper, zinc, glass fiber, or combinations thereof. In certain embodiments, the thermally conductive filler may be provided as flakes having an average volume of 5 to 75 mm3. In one or more embodiments, the thermally conductive filler may be loaded in the polymer material of the second body at 0.5 to 25% by weight.
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
According to one or more embodiments, a refrigeration appliance includes a water fill tube susceptible to freezing and a heating device, such as a foil heater. In certain embodiments, as described hereinafter, the water fill tube may be described with reference to an ice making system with an ice making compartment, however this is not intended to be limiting, and the water fill tube may be used for any water fill tube in the refrigeration appliance that is susceptible to freezing. In at least one embodiment, the water fill tube is constructed from a polymer material (e.g., high-density polyethylene (HDPE), cross-linked polyethylene (PEX), polyethylene (PE), or other suitable plastic that can withstand the environment within the refrigeration appliance) with a thermally conductive filler dispersed therein to improve heat transfer through the tube to prevent ice build-up and melt ice. In one or more embodiments, where the water fill tube is supplying water to the ice making system, the water fill tube may extend into the ice making compartment, such that the thermally conductive filler allows for heat to conduct into the portion of the water fill tube positioned within the ice making compartment. As such, thermally conductive filler improves heat transfer from the external foil heater to the ice formed within the water fill tube to reduce blockages within the water fill tube, and in embodiments where the water fill tube is supplying an ice making system, improve performance of the ice making system.
Referring to
The refrigeration appliance 100 may be constructed in any suitable manner, and the depiction of a refrigeration appliance 100 with a freezer compartment 110 configured as a drawer 112 and a refrigerator compartment 120 configured with french doors 122, 124 is not intended to be limiting. For example, the refrigeration appliance 100 may have a freezer compartment 110 and a refrigerator compartment 120 side by side, or in other examples, have the refrigerator compartment 120 below a freezer compartment 110, and may further have any suitable number of doors, compartments, and drawers to configure the refrigeration appliance 100.
In one or more embodiments, as shown in the example of
Referring to the examples of the ice making system 200 shown in
Although described as a water fill tube 240 for the ice making system 200, the water fill tube 240 may be any suitable water fill tube in the refrigeration appliance 100 such as the water tube supplying water to the dispenser 130. As such, although the water fill tube 240 will be described in the below examples with reference to the ice making assembly 200, any suitable water fill tube included in the construction of the refrigeration appliance 100 is contemplated, and discussion with the water fill tube with respect to the ice making system 200 is not intended to be limiting. Thus, even if the water fill tube 240 is not supplying the ice making system 200, it may still be susceptible to freezing based on the water fill tube being split between the outside of housing 210 and inside (e.g., being in the open cabinet vs. foamed in), and the water fill tube 240 may be constructed according to the embodiments described below, without limitation.
Referring to
In at least one embodiment, the water fill tube 240 comprises a body 241 (e.g., a tube) having an inner surface defining a cavity therein for flowing water to the ice making system 200, and an outer surface, opposite to the inner surface, extending about the periphery and along the length body. The body 241 may be formed from a single unitary polymer material, or include layers of the polymer material to form the body 241. In embodiments where the body 241 is a layered structure, one or more of the polymer materials may be used in the construction of the body. The thickness of the body 241 (as defined between the inner surface and the outer surface) may be, in some embodiments 0.5 to 2.0 mm, in other embodiments 0.75 to 1.75 mm, and in yet further embodiments 1.0 to 1.5 mm. Moreover, the body may have an outer diameter, from a center of the body 241 to the outer surface, of 5.5 to 8.5 mm in some embodiments, 5.75 to 8.25 mm in other embodiments, and 6.0 to 8.0 mm in yet other embodiments. Additionally, the body may have an inner diameter, from a center of the tubular body to the inner surface, of 3.5 to 6.0 mm in some embodiments, 3.75 to 5.75 mm in other embodiments, and 4.0 to 5.5 mm in yet other embodiments. The thickness may be formed via a single layer of polymer material or be constructed via layers forming the overall thickness of the body 241.
The polymer material may be HDPE, PEX, PE, or other suitable plastic that can withstand the temperatures (i.e., maintain its structural integrity) as based on the location of the water fill tube 240 the refrigeration appliance (e.g., in the refrigerator or freezer compartment 120, 110 interior, within the foamed in insulation, within the housing 210, and/or within the ice making system 200). In certain embodiments, the water fill tube 240 may include combinations of HDPE, PEX, PE or other suitable plastic. For example, the water fill tube 240 shown in
In certain embodiments, as shown in
In further examples (not shown), the polymer material forming the body 241 may be HDPE, such that the water fill tube 240 may be positioned within the insulation and/or the ice making compartment 230, and in other examples, where the polymer material is PEX, the water fill tube 240 may be inside the housing 210 but outside the ice making compartment 230. The water fill tube 240 may be formed using any suitable process based on the polymer material and the desired dimensions, such as, but not limited to, over-molding, injection molding, extruding, or combinations thereof. Generally, the water fill tube 240 of the present disclosure can be used in any suitable location where water may freeze within the line and have additional components to form the water fill tube such that the water fill tube 240 can be used in conjunction with an external heating device 300, described in further detail below.
The thermally conductive filler may be any suitable material that improves the thermal conductivity of the polymer material to increase heat transfer from the outside surface to the inside surface, and thus the cavity, when compared with a water fill tube that does not include the thermally conductive filler. Furthermore, the thermally conductive filler facilitates heat transfer along the length of the water fill tube 240, as based on the first portion 242, the second portion 244, or both including a thermally conductive filler. The thermally conductive filler may be, in some embodiments, a conductive powder, conductive flakes, or other conductive particles. The thermally conductive filler may be a suitable material for improving the thermal conductivity of the water fill tube 240, such as, but not limited to aluminum, zinc, graphite, copper, or other suitable thermally conductive filler (e.g., glass fibers), or combinations thereof, that can be loaded in the polymer matrix in flake, powder, fiber, or particle form. The inclusion of the thermally conductive filler improves the overall thermal conductivity of the water fill tube 240, as measured by ASTM E1461 and international standards DIN EN 821, DIN 30905 and ISO 22007-4:2008. In some embodiments, the thermal conductivity is increased by half to 20 times compared to the unfilled polymer material in some embodiments, half to 18 times in other in embodiments, and half to 16 times in yet further embodiments. As such, in examples where the polymer material is HDPE, the thermal conductivity may be, in some embodiments, at least 0.3 W/m-K in the temperature range of -15 to 40° C., and in other embodiments, at least 0.45 W/m-K. In some embodiments, the thermal conductivity may be increased to at least 1.0 W/m-K, and in other embodiments, the thermal conductivity may be increased to at least 2.0 W/m-K. In certain embodiments where the polymer material is HDPE, the thermal conductivity may be increased up to 4.8 W/m-K. In certain embodiments, the thermally conductive filler may be added in such amount such that the thermal conductivity may be increased to up to 5.5 W/m-K. As such, the thermal conductivity of the polymer material with the thermally conductive material may be 0.3 to 5.5 W/m-K. However, the thermal conductivity may vary based on the polymer material used, and the increase in thermal conductivity may be quantified by the multiplier (e.g., half to 20 times) of the thermal conductivity of the polymer material, and discussion of particular ranges is not intended to be limiting.
The thermally conductive filler may be loaded into the polymer material in any suitable quantity to improve the conductivity of the water fill tube 240. In some embodiments, the thermally conductive filler may be loaded in the polymer matrix as 0.5-25% by weight in some embodiments, 0.75-22.5% by weight in other embodiments, and 1.0-20% by weight in yet other embodiments. In some examples where the thermally conductive filler may be flakes (e.g., aluminum flakes), the individual flakes may have an average volume of 5 to 75 mm3 in some embodiments, 7 to 65 mm3 in other embodiments, and 9 to 60 mm3 in yet further embodiments. However, the size and shape of the thermally conductive filler may vary as based on the material selected as based on the required conductivity through the water fill tube 240 given environmental parameters and rating of the heating device. Features of the thermally conductive filler may be discussed with respect to the thermally conductive filler being aluminum flakes, however this is not intended to be limiting, and certain parameters may be selected based on the specific thermally conductive filler used for increasing the thermal conductivity of the water fill tube 240. In one or more embodiments, the water fill tube 240 with the thermally conductive filler may have a thermal conductivity of 0.3 W/m-k to 10.0 W/m-k in some embodiments, of 0.4 W/m-k to 7.5 W/m-k in other embodiments, and of 0.5 W/m-k to 5.0 W/m-k in yet further embodiments. However, the thermal conductivity may vary based on the polymer material used, and the increase in thermal conductivity may be quantified by the multiplier (e.g., half to 20 times) of the thermal conductivity of the polymer material, and discussion of particular ranges is not intended to be limiting.
The refrigeration appliance 100 further includes a heating device 300 positioned to supply heat to the outer surface of the water fill tube 240, such that the thermally conductive filler facilitates heat transfer through the body to the inner surface to melt ice formed inside the cavity of the water fill tube 240. The heating device 300 may be any suitable heating device for heating the water fill tube 240, including, but not limited to a foil heater. Referring to
In one or more embodiments, as shown in the example of
The refrigeration appliance 100 further includes a controller (not shown) configured to operate the heating device 300. The heating device 300 may be operated in any suitable manner, including, but not limited to, based on sensor feedback (e.g., ice presence/build up in the water tube), based on a percentage of time of the ice making cycle, or on a percentage of time, and the like. For example, upon receipt of data indicative of an ice blockage in a water tube, the controller may operate the heating device 300 to heat the first portion 242 of the water tube 240 such that ice can be melted. The sensor may be positioned in the first portion 242 or the second portion 244, or be located in both, with the time of operating the heating device varying based on the ability of the water fill tube 240 to conduct heat from the first portion 242 to the second portion 244 if ice is detected in the second portion 244.
According to one or more embodiments, a refrigeration appliance includes an ice making system with a housing having an ice making compartment within, a water fill tube extending through the housing into the ice making compartment, and a heating device positioned outside the ice compartment (and in some embodiments, outside the housing). The heating device may be any suitable heating device, such as a foil heater. The water fill tube has a first portion outside the ice making compartment and extending out of the housing through an aperture such that water can be routed into the ice making compartment, and a second portion positioned within the ice making compartment. At least a portion of the water fill tube is made of a polymer material with a thermally conductive filler dispersed therein. The thermally conductive filler improves heat transfer from an outer surface of the water fill tube to the inner cavity to prevent ice build-up and melt ice, and also allows for heat to conduct along the length of the water fill tube to facilitate heat transfer to the second portion within the ice making compartment. In certain embodiments, the second portion may include an end body positioned on the second portion, with the end body including the thermally conductive filler. Thus, the heating device can heat the water fill tube to heat the first portion directly, and facilitate melting ice in the second portion by improving thermal conduction via the thermally conductive filler. As such, the thermally conductive filler improves heat transfer from the heating device to the ice formed within the water fill tube to reduce blockages and improve performance of the ice making system.
Except where otherwise expressly indicated, all numerical quantities in this disclosure are to be understood as modified by the word “about”. The term “substantially,” “generally,” or “about” may be used herein and may modify a value or relative characteristic disclosed or claimed. In such instances, “substantially,” “generally,” or “about” may signify that the value or relative characteristic it modifies is within ± 0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the value or relative characteristic (e.g., with respect to transparency as measured by opacity). Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary, the description of a group or class of materials by suitable or preferred for a given purpose in connection with the disclosure implies that mixtures of any two or more members of the group or class may be equally suitable or preferred.
As referenced in the figures, the same reference numerals may be used herein to refer to the same parameters and components or their similar modifications and alternatives. For purposes of description herein, the terms “upper,” “lower,” “right,” “left,”“rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the present disclosure as oriented in
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
