Filter assembly for ice making appliance

A filter cartridge assembly for an ice making appliance having a rectilinear filter cartridge with a plurality of partitions that are positioned within an internal chamber, form multiple sub-chambers, and create a non-linear pathway for the flow of water through the filter cartridge. Filter media positioned in the sub-chambers of the filter cartridge are configured to remove dissolved solids from water travelling through the filter cartridge and used by the appliance to create ice, including clear ice.

FIELD OF THE INVENTION

The subject matter of the present disclosure relates generally to a deionization filter for an ice making appliance including a clear ice making appliance.

BACKGROUND OF THE INVENTION

Appliances that create ice provide a convenience in both commercial and residential applications. Ice may be used in liquid refreshments as well as food preparation and storage. Having an appliance that can be supplied with water to create and store ice may ensure such is readily available as needed and thereby avoid transport and storage of the same. The ice making appliance may be a stand-alone appliance or may be incorporated into another appliance such as refrigerator that includes a freezer compartment and/or an additional compartment dedicated to ice production.

“Clear ice” can be very desirable to certain consumers, particularly for use in liquid refreshments. As used herein, “clear ice” refers to ice that has been formed by an appliance through a process that reduces or eliminates air bubbles, particles, and dissolved solids in the ice so as create ice that is more transparent or clear for the passage of light as compared to ice formed by traditional or conventional processes. For example, ice can be formed by freezing water that has been poured into a receptacle. Air trapped in the resulting ice along with any particles and dissolved solids will increase the opacity of the ice. In contrast, the manufacture of clear ice may include filtering the water to remove particles and dissolved solids and then freezing the water in a manner that avoids trapping air in the ice as it forms. The resulting ice can be relatively clearer or more transparent than ice made without taking such steps and may also melt more slowly. For at least these reasons, certain consumers desire appliances that can provide such clear ice.

The manufacture of ice, and particularly clear ice, can consume significant amounts of water. For example, the ice making appliance may flow circulate water over an evaporator to chill the water into ice. Dissolved solids in the water will accumulate in each pass as the ice is formed and removed. In order to prevent the solids from precipitating and depositing on the evaporator, water is drained from the appliance and replaced with fresh water having a lower concentration of dissolved solids. The process is repeated resulting in a significant consumption of water that is not converted into ice.

In order to reduce the amount of dissolved solids, the water may be filtered. However, particulate filters may not remove dissolved solids. Additionally, conventional filters may consume valuable space that would more preferably be used for storage of the ice and/or other components of the ice making appliance. Limitations on available space may be particularly acute for stand-alone ice making appliances that are intended for convenient placement within a small space in cabinetry and/or under a countertop. Such appliances are already more compact relative to e.g., a refrigerator such that the addition of a filter may be impractical due to space constraints.

Accordingly, a device for filtering water for the manufacture of ice would be desirable. More particularly, a device for filtering water and removing dissolved solids in an appliance for manufacturing clear ice would be particularly useful. Such a device that can provide the desired amount of filtration while reducing the amount of space consumed by the filter in the appliance would also be particularly useful. An ice making appliance incorporating such a device would be useful. Such an appliance that can reduce or eliminate the amount of water used in making the ice would be particularly desirable.

BRIEF DESCRIPTION OF THE INVENTION

In one exemplary embodiment, the present invention provides a filter cartridge assembly for an ice making appliance. A filter cartridge thereof can define an internal chamber, the filter cartridge having a pair of generally parallel main walls separated by the internal chamber and connected by a first pair of end walls and a second pair of side walls. A fluid inlet is connected with the filter cartridge and provides for the flow of water into the internal chamber. A fluid outlet is connected with the filter cartridge and providing for the flow of filtered water out of the internal chamber.

A plurality of partitions may be positioned within the internal chamber, extending between the parallel main walls to form multiple sub-chambers, each partition defining a blocked end and an open end, the partitions spaced apart along a direction between the end walls to form a first group where the blocked end is connected to one of the side walls and a second group where the blocked end is connected with the other side wall. The partitions may define a non-linear pathway for the flow of water through the filter cartridge between the fluid inlet and the fluid outlet. Filter media is positioned in the sub-chambers of the filter cartridge. The filter media can be configured to remove dissolved solids from water travelling through the filter cartridge.

In another exemplary embodiment, the present invention provides an ice making appliance and includes a cabinet defining an interior. A door is supported by the cabinet and is configured for allowing selective access to the interior. An ice bin can be located within the interior of the cabinet and positioned to collect ice created by the ice making appliance. A cooling system is provided for converting water from a liquid to ice. A filter cartridge assembly provides for removing dissolved solids from the water. The filter cartridge assembly can include a filter cartridge having a rectilinear shaper and defining an internal chamber, the filter cartridge having a pair of generally parallel main walls separated by the internal chamber and connected by a first pair of end walls and a second pair of side walls. A fluid inlet is connected with the filter cartridge and provides for the flow of fluid into the internal chamber. A fluid outlet is connected with the filter cartridge and provides for the flow of fluid out of the internal chamber.

A plurality of partitions may be positioned within the internal chamber and extending between the parallel main walls to form multiple sub-chambers. The partitions are configured to form a serpentine pathway for the flow of water through the filter cartridge between the fluid inlet and the fluid outlet. Filter media is positioned in the sub-chambers of the filter cartridge. The filter media is configured to remove dissolved solids from water travelling through the filter cartridge.

Use of the same or similar reference numerals denotes the same or similar features unless otherwise noted.

DETAILED DESCRIPTION OF THE INVENTION

FIGS.1and2provide front views of an exemplary embodiment of an ice making appliance100of the present invention. As shown inFIG.1, ice making appliance100is installed in a cabinet110under a countertop112as might be found in residential or commercial applications. For this exemplary embodiment, ice making appliance100will be described with a deionization filter cartridge assembly300for making clear ice. However, in other exemplary embodiments, the present invention may provide water filtration for an ice making machine within another appliance such as a refrigerator that stores food items and may also be used for manufacturing regular ice as well as clear ice.

Ice making appliance100includes a cabinet104defining an interior126where ice130is created and stored in an ice bin120for ready access by a user. Ice bin120may include a hinged front door for ready access to the ice130. Cabinet104extends between a top portion106and a bottom portion108along vertical direction V and between a left side105and right side107as viewed inFIG.1along lateral direction L. A transverse direction T (e.g.,FIG.4) is orthogonal to both vertical direction V and lateral direction L and together the three define an orthogonal coordinate system.

Appliance100includes a front door102that can be supported by cabinet104and configured for allowing a user to open door102and selectively access interior126while also insulating interior126to conserve energy when closed. For this embodiment, door102is pivotably supported on hinges116and118. Other configurations and shapes for cabinet104and door102may be used as well.

A control panel128(FIG.2) is included in the top portion106of appliance100. Control panel128may include dials, buttons, or other features whereby a user may select various options for the operation of appliance100. A filter cartridge assembly300is also conveniently located in top portion106adjacent to control panel128and will be further described herein. Assembly300includes a handle352allowing the user to conveniently access and replace a filter cartridge302and/or filter media (FIG.4) located therein. Other locations and orientations for filter cartridge assembly300may also be used. A machinery compartment122is located in bottom portion108of appliance100behind grille124.

FIG.3provides a schematic illustration of an exemplary clear ice production system200for the creation of ice as may be used with appliance100. The operation of exemplary ice production system200will now be described. Using the teachings disclosed herein, one of ordinary skill in the art will understand that other ice production systems may be used within the scope of the present invention and claims that follow.

Water is provided to ice production system200from water supply204external to appliance100and may be e.g., a municipal or well-water supply associated with the commercial or residential application in which appliance100is installed. The water can be fed into a reservoir206located in ice making appliance100and from which main pump202draws water and supplies the same to filter cartridge assembly300. The pressure at which water is supplied to filter cartridge assembly300from pump202may be relatively low. For example, while the pressure of external water supply may range from 35 pounds per square inch (psi) to 120 psi, the non-zero pressure of water provided by pump202at filter cartridge assembly300may be 10 psi or less, 5 psi or less, or in the range x where 0≤x≤10 psi. This can provide advantages in the design of filter cartridge assembly300as will be further described.

The contents of water from supply204may vary considerably depending upon the geographic location, the amount and type of water treatment applied to supply204before use in appliance100, and other variables as well. For example, the pH, alkalinity, turbidity and other properties may vary dramatically. In the production of clear ice, as previously referenced, dissolved solids present in water supply204can be detrimental to the creation of clear ice having the desired level of clarity or transparency. Such dissolved solids may be present even if the water provided from supply204to reservoir206was previously filtered or otherwise treated. Accordingly, filter cartridge assembly300provides for the reduction and/or removal of dissolved solids from water provided from water supply204. As used herein, the term “water” includes potable water that may not be pure H2O and instead may include other potable substances including particles and dissolved solids.

Continuing withFIG.3, after filtration to removed e.g., dissolved solids, the filtered water is cooled by a refrigeration or cooling system218to at, or below, the freezing temperature of water (0° C. or 32° F.) using an evaporator208. By way of example, refrigeration system218may be a sealed system that includes components for executing a known vapor compression cycle to provide cooling in ice maker100. The components can include evaporator208, expansion device210, compressor212, and condenser214—all connected in a loop that is charged with a refrigerant. As will be understood by those skilled in the art, such sealed system218may include additional components, e.g., at least one additional evaporator, compressor, expansion device, and/or condenser. Thus, cooling or refrigeration system218is provided by way of example only. It is within the scope of the present subject matter for other configurations of a refrigeration or cooling system to be used as well.

Within cooling system218, refrigerant flows into compressor212, which operates to increase the pressure of the refrigerant. This compression of the refrigerant raises its temperature, which is lowered by passing the refrigerant through condenser214. Within condenser214, heat exchange with ambient air takes place so as to cool the refrigerant. A fan may operate to move air through grille124and across condenser214so as to provide forced convection for a more rapid and efficient heat exchange between the refrigerant within condenser214and the ambient air. The expansion device (e.g., a valve, capillary tube, or other restriction device) receives refrigerant from condenser214. From the expansion device, the refrigerant enters evaporator208. Upon exiting the expansion device and entering evaporator208, the refrigerant drops in pressure. Due to the pressure drop and/or phase change of the refrigerant, evaporator208is cool, e.g., relative to ambient air and/or liquid water. Evaporator208is positioned in thermal contact with water from filter cartridge assembly300. For example, water may be sprayed onto, or caused to flow across, evaporator208. The water is cooled and undergoes a phase change to ice130, which is stored in ice bin120.

Within ice bin120, the clear ice130may melt and the resulting water/condensate is collected and returned by a secondary pump216to water reservoir206. From there, the water/condensate may be mixed with water from supply204and the cycle just described repeated for the creation of clear ice. One exemplary advantage of the filter cartridge system300of the present invention is that it allows for the substantial reduction or removal of dissolved solids in water supply204. Because of this high efficiency, ice production system200is a drainless ice production system in one exemplary embodiment of the invention.

As used herein, “drainless ice production system” means that water is not drained from system200. In prior known systems, a certain amount of water fed to system200from supply204would be drained into a waste line instead of being consumed as ice. This is necessary to prevent the precipitation of dissolved solids on e.g., evaporator208. Water would be drained so that additional water can be added to not only replace what is removed through ice consumption but also to dilute water in the appliance and prevent the precipitation of dissolved solids—particularly onto evaporator208. As stated, in one exemplary embodiment as shown inFIG.3, ice production system200is drainless in that no water must be removed due to the level of filtration of dissolved solids provided by filter cartridge assembly300. Ice production system200is provided by way of example only. One of ordinary skill in the art will understand that other ice production systems may be used with the filter cartridge assembly300of the present invention in other embodiments of the invention.

FIG.4illustrates an exemplary embodiment of filter cartridge assembly300with a filter cartridge302removed from a filter manifold304for purposes of illustration. Filter manifold304defines a slot306for the insertion (arrow I) and removal (arrow R) of filter cartridge302therefrom. As such, for this exemplary embodiment, filter cartridge302can be readily replaced by the user by accessing the interior126of cabinet104and pulling cartridge302out using handle352. A new cartridge302can be similarly inserted. During insertion and removal, cartridge302can slide back and forth in transverse direction T along a pair of opposing guides384,386spaced apart from each other along lateral direction L.

Filter manifold304includes a latch mechanism344for releasably securing filter cartridge302within filter manifold304. Latch mechanism344includes a resilient latch arm346supported on a top wall361of manifold304and extending away from manifold304as shown. Latch arm346includes a stop348extending orthogonally from latch arm and positioned to selectively block the removal of filter cartridge302from filter manifold304. The user can lift latch arm346to provide for convenient removal of filter cartridge302and replacement when needed.

Referring now toFIGS.4through9, filter cartridge302is rectilinear in shape and defines an internal chamber330that is divided into a plurality of sub-chambers332,334,336,336,340, and342(FIG.6) into which filter media400,402,404,406,408, and410(FIG.7) has been placed, respectively. As shown, the sub-chambers are also rectilinear in shape. Filter cartridge302includes a pair of generally parallel and opposing main walls312and314separated from each other along vertical direction V by chamber330for this exemplary embodiment. As used herein, “generally parallel” means forming an angle of 2 degrees or less from each other. Main walls312and314are connected by i) a first pair of opposing end walls320and322separated along lateral direction L by chamber330and ii) a second pair of opposing side walls316and318separated along transverse direction T by chamber330. Sidewall316includes handle352. In one exemplary embodiment, the low pressure of unfiltered water UW (FIG.6) provided to filter cartridge302allows for the rectilinear shape. This shape in turn allows to more effective filtration (as compared to cylindrical filters required for higher pressure) because increased contact between the water and filter media in a more compact space can be provided.

Filter cartridge assembly300includes a fluid inlet308connected with filter cartridge302and a fluid outlet310also connected with the filter cartridge. As shown inFIG.6, fluid inlet308provides a connection for the flow of unfiltered water (arrow UW) into internal chamber330and fluid outlet310provides a connection for the flow of filter water (arrow FW) out of internal chamber330. Fluid inlet308and fluid outlet310are each provided with an O-ring seal396and398(FIG.5), respectively. Other types of seals may also be used.

On rear wall390(cross-sectional view inFIG.9), filter manifold304includes a fluid inlet socket380and also includes a similar fluid outlet socket382(FIG.4). As shown by way of example inFIG.9, fluid inlet socket380releasably receives fluid inlet308into socket380when filter cartridge302is inserted into filter manifold304and is sealed by O-ring396. Similarly, fluid outlet socket382releasably receives fluid outlet310into socket382when filter cartridge302is inserted into filter manifold304and is sealed by O-ring398. Other types of connections may also be utilized with the scope of the present invention. Fluid inlet socket380and fluid outlet socket382can be connected with a water line-in392and a water line-out394(FIG.3).

Continuing with reference toFIGS.6,7, and8, a plurality of partitions324,325,326,327, and328are positioned within internal chamber300and divide it into the sub-chambers332,334,336,338,340, and342. Each partition extends orthogonally to, and between, main walls312and314. For this embodiment, the partitions are parallel to each other and orthogonal to sidewalls316and318. With reference to the passage of water through the filter cartridge302, each partition defines a blocked end B where fluid is precluded from passage and an open end O where fluid is allowed to pass. The arrangement of the partitions, including the blocked and open ends, creates a non-linear and, more particularly, serpentine path for the passage of fluid (arrows F) through chamber330between fluid inlet308and fluid outlet310.

Specifically, the partitions include a first group of partitions324,326, and328that each have a blocked end B that is connected to side wall318of cartridge302. The other end O of each of the first group of partitions324,326, and328is not connected to side wall316. Instead, a small gap exists between open end O and side wall316where porous media portions412,414, and416are positioned. For example, porous media portions may be constructed of a non-woven fibrous pad that allows for the passage of water (arrows F) between adjacent sub-chambers while preventing the passage or movement of filter media400,402,404,406,408, and410positioned in sub-chambers332,334,336,338,340, and342, respectively (FIG.7). Accordingly, water may pass around the open end O of partitions324,328, and328but is precluded from flowing around blocked ends B. Other types of porous media portions may also be used.

The partitions includes a second group of partitions325and327that have a blocked end B that is connected to side wall316of filter cartridge302. The other end O of each of the second group of partitions325and327is connected to side wall318. The second end O of partitions325and327includes apertures418and420, respectively, defined by partitions325and327, and through which water may flow between adjacent sub-chambers while simultaneously restricting the movement of filter media therebetween. In one exemplary embodiment, partitions325and326are also removable from filter cartridge302whereas partitions324,326, and328are integrally formed with filter cartridge302. A different number of partitions and sub-chambers may be used in other embodiments of the invention.

In one exemplary embodiment, the filter media contained in filter cartridge302includes one or more deionization resins that remove dissolved solids from the water as it flows (arrows F) through filter cartridge302between fluid inlet308and fluid outlet310so as to enable the production of clear ice. The filter media may be constructed from both anion resins and cation resins in the form of beads. For example, filter media400,402,404,406,408, and410may be alternated between a cation resin and an anion resin along lateral direction L. Optionally, each such media may include a mixed-bed media of both cation resin and anion resin. By way of example, the resins may be constructed from polymer beads that remove various mineral ions from the water as is flows through cartridge302. Other filter media for removing dissolved solids, particulates, and/or other contaminants may be used as well.

As mentioned, the rectilinear shape and partitioned configuration of filter cartridge302desirably provides for high efficiency filtration of e.g., dissolved solids while also providing a filter than can be readily fitted within the limited space of appliance100. In addition, filter cartridge assembly300can be conveniently located so that the user can readily remove and replace cartridge302and/or the filter media as needed when e.g., filter media400,402,404,406,408, and410is consumed or spent. Although shown in an orientation inFIG.2where the main walls314and314are oriented horizontally, one of ordinary skill in the art will understand that other orientations and locations within appliance100may also be used within the spirit and scope of the present invention and claims that follow.

Additionally, the present invention includes other embodiments, an example of which is shown inFIG.10. For this exemplary embodiment, filter cartridge assembly does not include a manifold304. Instead, fluid inlet308and310are connected directly with water lines392and394. For this embodiment, side wall316is configured as a door having handle352for the removal of wall316from the front of cartridge302(compareFIGS.10and11). A seal can be provided between side wall316and the front surface372(FIG.11) of filter cartridge302to prevent the leakage of water. The user can remove wall316and individually replace filter media400,402,404,406,408, and410in sub-chambers332,334,336,338,340, and342as denoted by arrow M for filter media400. The internal construction and flow of water through cartridge302is otherwise as described with reference to the embodiments ofFIGS.4through8. One or more latch mechanisms344,354,364, and374with latch arms346,356,366, and376equipped with stops348,358,368, and378operating as previously described may be used as well.