Refrigerated compartment air distribution assembly

The refrigeration appliance includes a wrapper forming an exterior of the refrigeration appliance and a refrigeration compartment liner and a freezer compartment liner within the wrapper. The wrapper, the refrigeration compartment liner, and the freezer compartment liner are in a spaced apart configuration forming a refrigeration compartment and a freezer compartment. A door is configured to provide access to and seal the freezer compartment. The door has a seal around a periphery thereof. A mullion is disposed between the refrigeration compartment liner and the freezer compartment liner. The mullion includes a forward portion extending towards the freezer compartment. The forward portion includes at least one air-deflection surface. A fan is operably coupled with an evaporator and is configured to direct cooled air within the freezer compartment. The fan is offset from the evaporator and configured to direct air at the air-deflection surface.

FIELD

The present disclosure generally relates to refrigerated appliances, and more particularly relates to freezer compartments of the refrigerated appliance having air distribution assemblies therein.

BACKGROUND

Refrigerated appliances commonly define one or more compartments therein that are accessible through a door. The door, in most instances, includes a seal there around. To maintain high efficiency of the appliance, the seal around the door should be airtight and condensation on the seal should be minimized.

SUMMARY

According to one aspect of the present disclosure, a refrigeration appliance is disclosed. The refrigeration appliance includes a wrapper forming an exterior of the refrigeration appliance. The refrigeration appliance further includes a refrigeration compartment liner and a freezer compartment liner. The wrapper, the refrigeration compartment liner, and the freezer compartment liner are in a spaced apart configuration forming a refrigeration compartment and a freezer compartment. A door is configured to provide access to and seal the freezer compartment. The door has a seal around a periphery thereof. A mullion is disposed between the refrigeration compartment liner and the freezer compartment liner. The mullion includes a forward portion extending towards the freezer compartment. The forward portion includes at least one air-deflection surface. A fan is operably coupled with an evaporator and is configured to direct cooled air within the freezer compartment. The fan is offset from the evaporator and configured to direct air at the air-deflection surface.

According to another aspect of the present disclosure, a freezer compartment for a refrigeration appliance is disclosed. The freezer compartment includes a wrapper forming an exterior of the refrigeration appliance. A liner is disposed in a spaced apart configuration from the wrapper. A door is configured to provide access to and seal the freezer compartment. A seal is disposed around a periphery of the door. A mullion is attached to the liner and includes a forward portion. The forward portion of the mullion includes at least one air-deflection surface. A fan is configured to direct cooled air within the freezer compartment. The fan is offset from an evaporator and is configured to direct air towards the air-deflection surface.

According to another aspect of the present disclosure, a refrigeration appliance is disclosed. The refrigeration appliance includes a wrapper forming an exterior of the refrigeration appliance. A liner is disposed in a spaced apart configuration from the wrapper and defines a compartment. A door is configured to provide access to and seal the compartment. A seal is disposed around a periphery of the door. At least one air-deflection surface extends inwardly of the seal and is configured to substantially redirect airflow from a fan. An axis of airflow from the fan is directed at the air-deflection surface.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring toFIGS. 1-7, a refrigeration appliance10includes a wrapper12forming an exterior of the refrigeration appliance10. The refrigeration appliance10further includes a refrigeration compartment liner14and a freezer compartment liner16. The wrapper12, the refrigeration compartment liner14, and the freezer compartment liner16are in a spaced apart configuration forming a refrigeration compartment18and a freezer compartment20. A door22is configured to provide access to and seal the freezer compartment20. The door22has a seal24around a periphery thereof. A mullion26is disposed between the refrigeration compartment liner14and the freezer compartment liner16. The mullion26includes a forward portion28extending towards the freezer compartment20. The forward portion28includes at least one air-deflection surface30. A fan32is operably coupled with an evaporator34and is configured to direct cooled air within the freezer compartment20. The fan32is offset from the evaporator34and configured to direct air at the air-deflection surface30.

Referring now toFIG. 1, a refrigeration appliance10is shown having a front surface36that is generally disposed around a front opening38(FIG. 2) of a refrigeration compartment18(FIG. 2). The refrigeration compartment18is contemplated to be an insulated space for storing fresh food items having first and second doors40,42that are rotatably coupled to the front surface36of the refrigeration compartment18for selectively providing access to the refrigeration compartment18. In the embodiment shown inFIG. 1, a freezer door22is configured to selectively provide access to a freezer compartment20disposed below the refrigeration compartment18. As illustrated, according to one embodiment, the freezer compartment20is arranged in a bottom mount configuration in the refrigeration compartment18. Although the freezer compartment20is shown as the “bottom freezer” type, the teachings set forth herein are applicable to other types of cooling appliances, including but not limited to, side-by-side refrigerator/freezers, top mount freezers, etc. Accordingly, embodiments of the present disclosure are therefore not intended to be limited to any particular type and/or configuration of the refrigeration appliance10.

Referring now toFIG. 2, the refrigeration appliance10is shown with the first and second doors40,42and the freezer door22removed to reveal the refrigeration compartment18and the freezer compartment20, which are separated by a mullion26. In the embodiment ofFIG. 2, a number of shelves44are shown disposed in the refrigeration compartment18and are contemplated to be vertically adjustable therein. The refrigeration compartment18also includes a number of drawers46for storing various items, such as fresh fruits and vegetables, in specific temperature controlled environments.

The refrigeration appliance10includes an exterior wrapper12, which includes first and second side walls48,50, top wall52and rear wall54. The exterior wrapper12may be a metal component formed of a sheet metal material, and/or any other practicable material.

The refrigeration appliance10further includes a refrigeration compartment liner14, which includes first and second side walls56,58, top wall60, rear wall62and bottom wall64that define the refrigeration compartment18. The freezer compartment20includes a freezer compartment liner16having first and second side walls66,68, a top wall70, a bottom wall72, and a back wall74. In some embodiments, the top wall60and/or bottom wall64of the refrigeration compartment18may be formed by the mullion26rather than the refrigeration compartment liner14. Likewise, in some embodiments, the top wall70and/or bottom wall72of the freezer compartment20may be formed by the mullion26rather than the freezer compartment liner16.

The refrigeration compartment liner14and freezer compartment liner16are spaced-apart from the exterior wrapper12to provide an insulating space therebetween. According to various examples, the refrigeration appliance10may include one or more vacuum insulated structures to aid in decreasing thermal conductivity between an interior and exterior of the appliance10. In vacuum insulated structures, heat transmission through the vacuum insulated structure is decreased by creating a vacuum between the exterior walls of the structure. By creating a vacuum between the spaces intended to be thermally isolated, heat conduction is minimized because there is no, or less, material (e.g., air) to transfer the thermal energy between the thermally isolated spaces. For example, the wrapper12and the liners14,16serve as the exterior and interior surfaces of the vacuum insulated structure, respectively. The wrapper12and the liners14,16are configured in a spaced apart relationship to define a space therebetween. The space between the wrapper12and the liners14,16may have an air pressure of less than about 1 atm, about 0.5 atm, about 0.4 atm, about 0.3 atm, about 0.2 atm, about 0.1 atm, or less than about 0.01 atm. The wrapper12and/or the liners14,16may be composed of a metal (e.g., stainless steel), a polymer, any other practicable material, and/or combinations thereof.

Referring toFIGS. 3A and 3B, the freezer compartment20is sealed through any type of closure known in the art. According to one embodiment, a two-piece door22is provided on a slidable assembly76that is coupled to the freezer compartment20(e.g., the freezer compartment liner16) and/or any other portion of the refrigeration appliance10. The slidable assembly76may move the door22between a first, closed position and a second, open position in conjunction with the use of a handle104, or any other feature on the exterior of the refrigeration appliance10. It will be appreciated, however, that the door22may be attached to any portion of the refrigeration appliance10through any means known in the art without departing from the teachings provided herein.

The door22includes an inner panel78and an outer panel80that are configured in a spaced apart relationship to define a space therebetween. The door22, itself, may be a vacuum insulated structure, as explained above. In alternate embodiments, insulation may be provided between the inner and outer panels78,80, such that the door22is insulated. Alternatively, the door22may be formed from a single, integrally formed panel that is configured to insulate the freezer compartment20.

A seal24, or compressible gasket, is provided around the outer perimeter of the door22. The seal24may be composed of a rubber, a polymeric material or any other soft and pliable material configured to create a seal between the door22and the front surface36, or any other exterior portion of the refrigeration appliance10. The seal24helps maintain the lower temperature of the freezer compartment20, as compared to a higher temperature of the refrigeration compartment18.

Referring toFIG. 4-7, the fan32is operably coupled with the evaporator34, as will be described in greater detail below. The fan32may be a component of a fan module92that further includes a fan housing110. The fan housing110may be made out of molded plastics, metals, and other types of substantially rigid materials. A fan wiring harness may be disposed within the housing110and may be in communication with the fan32and any additional electrical modules and/or other controls.

Referring still toFIGS. 4-7, the fan32, according to one embodiment, is operably coupled with the evaporator34for drawing air from the freezer compartment20and passing that air through the evaporator34. The fan module92includes the fan32, a motor108, a support bracket110, and the fan housing110. The motor108may be any fan motor having a drive shaft extending along a central longitudinal axis. The drive shaft, according to one embodiment, may be downwardly extending. A central hub of the fan32may define a central axis that is mounted to a drive shaft of the associated motor108. In some instances, an axis of airflow from the fan32may be transverse to the central axis. The central hub of the fan32may be of any practicable shape and size to connect to a shaft extending from the motor108. Any additional components, such as any fasteners or spacers, may be attached to the central hub of the fan32through any methods known in the art, such as, but not limited to, vibration welding or adhesives.

The motor108is mounted to the support bracket110, which is mounted to a suitable support member (e.g., the back wall74of the freezer compartment liner16or a portion of the evaporator34). In one embodiment, an electronically commutated (EC), a shaded pole, permanent split capacitor (PSC) motor, and/or any other type of motor known in the art is implemented. The motor108may also be a direct current (DC) motor with an electronic commutation control that makes the drive shaft rotate.

The fan housing110may partially encompass the fan32and may include an air outlet112on a forwardly portion of the housing110. The air outlet112may include a grille114having one or more vanes116that may be orientated in any direction, including, but not limited to, a substantially vertical and/or a substantially horizontal orientation. The vanes116may direct airflow from the fan32in a desired direction and/or towards a predefined location. Accordingly, in operation, the fan32may direct airflow through the air outlet112, and subsequently, the grille114. The vanes116disposed in the grille114may further direct the airflow towards the side walls66,68, the mullion26, and/or the air-deflection surface30. The airflow directed towards the air deflection surface30may then be redirected by the air deflection surface30in a direction that prevents the airflow from the fan32from making direct contact with the seal24after leaving the air outlet112of the housing110.

It is contemplated that the vanes116may direct air in any direction without departing from the teachings provided herein. Moreover, the vanes116may be fixedly attached, or integrally formed, with the fan housing110. Alternatively, some or all of the vanes116may be reconfigurable to redirect the airflow in one or more desired directions.

With further reference toFIG. 4, the fan32has a plurality of blades disposed circumferentially at spaced intervals about the central hub. For example, four blades are disposed at spaced intervals of ninety (90) degrees about the circumference of the central hub. The fan blades may be of any practicable shape, such as a teardrop shape.

Referring toFIG. 5, the refrigeration appliance10includes a machinery compartment82that at least partially contains components for executing a known vapor compression cycle for cooling air in the refrigeration compartment18and/or the freezer compartment20. The components include a compressor84, a condenser86, an expansion device88, and the evaporator34, which includes an evaporator coil90, connected in series and charged with a refrigerant. The evaporator34is a type of heat exchanger that transfers heat from air passing over the evaporator34to a refrigerant flowing through the evaporator34, thereby causing the refrigerant to vaporize. The cooled air is used to refrigerate one or more refrigeration compartment(s)18and/or freezer compartment(s)20via the fan32. The refrigeration compartment18and the freezer compartment20may share one or more components for executing the compression cycle. Alternatively, each compartment18,20within the refrigeration appliance10may include its own dedicated components.

In the embodiment shown inFIG. 5, the fan32is disposed above the evaporator34. The evaporator34is configured to provide cooled air to the freezer compartment20. The fan32, as illustrated, is at an offset angle from the evaporator34such that the fan32directs airflow towards the top surface of the freezer compartment20, as will be described in great detail below. According to one aspect, an angle between an axis of airflow of the fan32and the freezer compartment liner16is between one (1) degree and eighty-nine (89) degrees. The evaporator34may be disposed in a substantially parallel position to the back wall74of the freezer compartment liner16.

The mullion26is integrally formed with, or attached to, the top surface of the freezer compartment20and includes a laterally extending portion94and the forward portion28that extends downwardly from the laterally extending portion94. The downwardly extending forward portion28includes the air-deflection surface30. The air-deflection surface30may include one or more curved surfaces, as will be described in greater detail below. The air-deflection surface30may also or alternatively include one or more planar surfaces. The air-deflection surface30may be configured to redirect airflow from the fan32from a first direction96to a second direction98. According to at least one embodiment, the first direction96is substantially forwardly and the second direction98is a mixture of downwardly and/or forwardly. According to one embodiment, the second direction98may be offset from the first direction96by an offset angle θ between ten (10) degrees and one hundred and eighty (180) degrees. In some embodiments, the offset angle θ may be greater than hundred and eighty (180) degrees.

Accordingly, it is contemplated that a portion of the airflow will be redirected away from the seal24surrounding the door22prior to contacting the seal24. The redirected airflow may instead contact an inner surface100of the door22and/or the bottom wall72of the freezer compartment20. Accordingly, as a result of the airflow from the fan32coming into direct contact with the air-deflection surface30rather than the seal24, the air-deflection surface30may have a lower temperature than an inner surface of the seal24. Consequently, under most conditions, the seal24will remain at temperatures above the dew point of ambient air that surrounds the refrigeration appliance10. Thus, the seal24may be free of condensation and frost build up. By minimizing condensation buildup on the seal24, electrical requirements of the refrigeration appliance10may be substantially reduced over conventional freezer assemblies.

Referring toFIG. 6, according to at least one embodiment, the air-deflection surface30is configured such that airflow from the fan32contacts the air-deflection surface30and is redirected towards the bottom wall72of the freezer compartment20. Thus, the assembly, as described herein, redirects the cooled air from the first direction96to the second direction98, to form an air curtain along a front portion102of the freezer compartment20. It is further contemplated that the air curtain may be provided for accelerated air flow when the door22is opened in order to keep cooled air within the freezer compartment20while a user keeps the door22in an open position. Accordingly, leakage of the cooled air through the opening of the freezing compartment20is partially prevented, so that temperatures in the freezing compartment20do not rise as quickly, or in a significant amount, when the door22is placed in the second position, thereby enhancing the cooling efficiency of the refrigeration appliance10.

Referring now toFIG. 7, the opposing side walls66,68of the freezer compartment20may additionally, or alternatively, include air-deflection surfaces30on a portion thereof such that airflow that is directed at and/or along the side walls66,68is further redirected towards a central portion106of the freezer compartment20. As described above, the air-deflection surfaces30may prevent some of the airflow from directly contacting the seal24, thereby reducing the condensation on the seal24.

Moreover, a first air curtain may be formed by the air-deflection surface30on the mullion26and a second, and in some embodiments, a third, air curtain may be formed by one or more of the side walls66,68. The airflow that is redirected by the air-deflection surface30on the mullion26may be offset from the airflow that is redirected by the one or more air-deflection surfaces30on the side walls66,68. For example, the air-deflection surface30of the mullion26may be direct airflow towards a point P1that is offset, vertically and/or laterally, from the airflow from the one or more air-deflection surfaces30of the side walls66,68, which may be directed towards a second point P2.

The freezer compartment20having at least one air deflecting surface may enhance the sealing abilities of the seal24by minimizing condensation thereon that is formed when the seal24is in a direct path with the cold air distributed by the fan32within the freezer compartment20. By improving the sealing ability of the seal24, the refrigeration appliance's10energy efficiency and perceived quality may also be enhanced.

The freezer compartment20may also afford more comprehensive circulation patterns, which may create a more uniform temperature within the freezer compartment20whether or not the freezer compartment20is empty, loaded, and/or partially loaded. When the freezer compartment20is in a lightly loaded condition, improved airflow circulation patterns provided by the assembly set forth herein allows air to flow around items, cooling the freezer compartment20and reducing the possibility of stagnant air. When the freezer compartment20is in a heavily loaded condition, the assembly set forth herein forces air to flow over the items in the freezer compartment20, which continues to circulate air throughout freezer compartment20.