Ice making system for refrigerator appliance

A refrigerator appliance includes a cabinet defining a fresh food chamber and a freezer chamber below the fresh food chamber. The refrigerator appliance further includes an ice maker disposed within the cabinet outside of the freezer chamber and proximate to the fresh food chamber. The ice maker includes an ice making chamber. The ice maker is in thermal communication with the freezer chamber and the ice making chamber is not in fluid communication with the freezer chamber.

FIELD OF THE INVENTION

The present subject matter relates generally to refrigeration appliances, and more particularly to refrigeration appliances including features for making ice.

BACKGROUND OF THE INVENTION

Generally, refrigerator appliances include a cabinet that defines a fresh food chamber for receipt of food items for storage. Many refrigerator appliances further include a freezer chamber for receipt of food items for freezing and storage. Certain refrigerator appliances include an ice maker. In order to produce ice, liquid water is directed to the ice maker and frozen. Accordingly, refrigerator appliances having both an ice maker and a freezer chamber commonly include the ice maker in the freezer chamber since both operate at or around the same general temperatures. However, in many currently utilized refrigerator appliances, the freezer chamber is positioned below the fresh food chamber, which is sometimes referred to as a bottom freezer. In such refrigerator appliances, locating the ice maker in the bottom freezer may be inconvenient or otherwise not desired.

Accordingly, an ice making system for a refrigerator appliance with features permitting operation remote from the freezer chamber would be useful.

BRIEF DESCRIPTION OF THE INVENTION

A refrigerator appliance includes a cabinet defining a fresh food chamber and a freezer chamber below the fresh food chamber. The refrigerator appliance further includes an ice maker disposed within the cabinet outside of the freezer chamber and proximate to the fresh food chamber. The ice maker includes an ice making chamber. The ice maker is in thermal communication with the freezer chamber and the ice making chamber is not in fluid communication with the freezer chamber. Additional 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 accordance with one embodiment, a refrigerator appliance is disclosed. The refrigerator appliance includes a cabinet defining a fresh food chamber and a freezer chamber, the freezer chamber positioned below the fresh food chamber along a vertical direction, the cabinet also includes an an icebox compartment outside of the freezer chamber and proximate to the fresh food chamber. The cabinet further includes a heat exchange opening at the icebox compartment. The refrigerator appliance also includes an ice maker disposed within the icebox compartment, the ice maker including a heat exchanger positioned at the heat exchange opening.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1is a front view of an exemplary embodiment of a refrigerator appliance100. Refrigerator appliance100extends between a top portion101and a bottom portion102along a vertical direction V. Refrigerator appliance100also extends between a first side portion105and a second side portion106along a horizontal direction H. A transverse direction T (FIG. 2) may additionally be defined perpendicular to the vertical and horizontal directions V, H.

Refrigerator appliance100includes a cabinet or housing120defining an upper fresh food chamber122and a lower freezer chamber124arranged below the fresh food chamber122on the vertical direction V. As such, refrigerator appliance100is generally referred to as a “bottom mount refrigerator.” In the exemplary embodiment, housing120also defines a mechanical compartment (not shown) for receipt of a sealed cooling system (not shown). Using the teachings disclosed herein, one of skill in the art will understand that the present invention can be used with other types of refrigerators (e.g., side-by-sides) or any other types of appliance as well. Consequently, the description set forth herein is for illustrative purposes only and is not intended to limit the invention in any aspect.

Refrigerator doors126are rotatably hinged to an edge of housing120for accessing fresh food chamber122. It should be noted that while two doors126in a “French door” configuration are illustrated, any suitable arrangement of doors utilizing one, two or more doors is within the scope and spirit of the present disclosure. A freezer door130is arranged below refrigerator doors126for accessing freezer chamber124. In the exemplary embodiment, freezer door130is coupled to a freezer drawer (not shown) slidably coupled within freezer chamber124.

Operation of the refrigerator appliance100can be regulated by a controller134that is operatively coupled to a user interface panel136. Panel136provides selections for user manipulation of the operation of refrigerator appliance100such as e.g., temperature selections, etc. In response to user manipulation of the user interface panel136, the controller134operates various components of the refrigerator appliance100. The controller may include a memory and one or more microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of refrigerator appliance100. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In some embodiments, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor.

The controller134may be positioned in a variety of locations throughout refrigerator appliance100. In the illustrated embodiment, the controller134may be located within the door126. In such an embodiment, input/output (“I/O”) signals may be routed between the controller and various operational components of refrigerator appliance100. In one embodiment, the user interface panel136may represent a general purpose I/O (“GPIO”) device or functional block. In one embodiment, the user interface136may include input components, such as one or more of a variety of electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. The user interface136may include a display component, such as a digital or analog display device designed to provide operational feedback to a user. The user interface136may be in communication with the controller via one or more signal lines or shared communication busses.

FIG. 2is a perspective view of refrigerator appliance100having refrigerator doors126in an open position to reveal the interior of the fresh food chamber122. Additionally, freezer door130is shown in an open position to reveal the interior of the freezer chamber124.

Referring now toFIGS. 2 and 3, a door126of the refrigerator appliance100may include an inner surface150and an outer surface152. The inner surface150generally defines the interior of the fresh food chamber122when the door126is in a closed position as shown inFIG. 1, while the outer surface152is generally opposite the inner surface150and defines the exterior of the refrigerator appliance100.

As shown for example inFIG. 3, an ice making system200may be provided outside of the freezer chamber124and proximate to the fresh food chamber122, e.g., in one of the doors126, such as disposed in a compartment160, which may be referred to as an icebox compartment160, defined at the inner surface150of one of the doors126. In such embodiments, the ice making system200may be disposed at least partially within the fresh food chamber122when the door126is in the closed position. Ice making system200may include an ice making chamber202where ice may be formed in a mold body210. Ice making system200may also include an ice storage bin204disposed in communication with the mold body210, e.g., below mold body210, for receipt and storage of ice once the ice has been formed in mold body210.

The ice making system200may, as discussed herein, be in thermal communication with freezer chamber124. In some exemplary embodiments, the ice making chamber202may not be in fluid communication with the freezer chamber124. In other words, in such embodiments, the ice making chamber202may be isolated from the freezer chamber. For example, in such embodiments, thermal communication between ice making system200and freezer evaporator170may be by convection, i.e., air flow, from evaporator170to a heat exchanger206and by conduction from heat exchanger206to the mold body210in the ice making chamber202. Providing cold air from the evaporator170to heat exchanger206rather than into ice making chamber202may permit more efficient thermal energy transfer from the cold air to the ice maker mold body210. That is, rather than circulating cold air above the mold body210, impinging a flow of cold air on the heat exchanger206which is in direct conductive thermal communication with the mold body210allows the cold air to more directly influence the mold body210. As a result, the ice making system200may be more efficient and provide faster ice production.

In general, the ice making system200and various components thereof, may be provided with insulation164(FIG. 4) to reduce heat exchange between the ice making system200and the fresh food chamber122as well as between ice making system200and the ambient environment, e.g., such that the temperature within ice making chamber202and ice storage bin204can be maintained at levels different from, e.g., cooler than, the temperature in the fresh food chamber122. The ice compartment160may include a heat exchange opening162. The ice maker compartment160may be otherwise completely enclosed by insulation164, except at the heat exchange opening162. In exemplary embodiments, various features for providing access to ice stored in the ice storage bin may be provided. In one example, an insulated door may be provided in the compartment160for access to the ice storage bin. In other embodiments, the outer surface of door126may include a dispenser feature, as is generally understood by those skilled in the art, which extends through the insulation164on the opposite side of compartment160from the fresh food chamber122when door126is in the closed position.

Turning back toFIG. 1, in some exemplary embodiments, ice from storage bin204may be supplied to dispenser recess140on the outer surface152of refrigerator door126. In such embodiments, refrigerator appliance100may include a dispenser assembly, e.g., for delivering or dispensing ice. Dispenser assembly may include a dispenser142positioned on or mounted to an exterior portion of refrigerator appliance100, e.g., on one of refrigerator doors126. Dispenser142may include a discharging outlet144for accessing ice. An actuating mechanism146, shown as a paddle, may be mounted below discharging outlet144for operating dispenser142. In alternative exemplary embodiments, any suitable actuating mechanism may be used to operate dispenser142. For example, dispenser142can include a sensor (such as an ultrasonic sensor) or a button rather than the paddle. Discharging outlet144and actuating mechanism146may be external parts of dispenser142which may be mounted in a dispenser recess140. Dispenser recess140may be positioned at a predetermined elevation convenient for a user to access ice or water and enabling the user to access ice without the need to bend-over and without the need to open refrigerator doors126. In some exemplary embodiments, dispenser recess140may be positioned at a level that approximates the chest level of a user.

In some exemplary embodiments, an access door—e.g., icebox door166(FIG. 2)—may be hinged to icebox compartment160to selectively cover or permit access to opening of icebox compartment160. In such embodiments, icebox door166permits selective access to icebox compartment160. Any manner of suitable latch168may be provided with icebox compartment160to maintain icebox door166in a closed position. In some exemplary embodiments, latch168may be actuated by a consumer in order to open icebox door166for providing access into icebox compartment160. In exemplary embodiments which include icebox door166, insulation164is provided throughout icebox door166for thermally isolating or insulating icebox compartment160from fresh food chamber122.

In some embodiments, for example as illustrated inFIGS. 4 and 5, a gasket163may be provided at an outer surface of the icebox compartment160. The gasket163may enclose heat exchange opening162. When the door126is in a closed position, gasket163may sealingly engage a side wall123of the fresh food chamber122to prevent air leakage when the door126is in a closed position. For example, gasket163may help to prevent or minimize cold air flowing between supply duct172and return duct178from escaping into the fresh food chamber122and/or relatively warm, humid air from fresh food chamber122from entering return duct178or contacting heat exchanger206. In alternative embodiments, gasket163may be positioned on side wall123of the fresh food chamber122and extend between side wall123and the outer surface of the icebox compartment160at heat exchange opening162when door126is in the closed position.

Although the gasket163prevents or minimizes relatively warmer and more humid air from fresh food chamber122or the ambient environment from contacting the heat exchanger206when the door126is in the closed position, when the door126is opened, condensation may gather on heat exchanger206which may lead to frost formation on heat exchanger206. In such cases, because the cold air from the evaporator170tends to be relatively dry (i.e., low humidity), it may provide sublimation defrosting of the heat exchanger206. That is, because the humidity of the air from the evaporator170is so low, some or all frost which may form on the heat exchanger206may evaporate when exposed to air from evaporator170passing over it. As such, any water which collects on the heat exchanger206in the form of condensation will travel at least partly as water vapor through ducts172and178rather than as liquid water, i.e., liquid water in ducts172and178is avoided or minimized.

Various components may be utilized to facilitate the temperature variance between ice making system200and fresh food chamber122. For example, in one embodiment, ice making system200may be in fluid communication with the freezer chamber124. As shown, e.g., inFIGS. 2 and 3, in some embodiments, the ice making system200may be in fluid communication with an evaporator170which may be disposed in or near the freezer chamber124. In some embodiments, supply duct172and return duct178may extend between and provide the thermal communication between the ice making system200and freezer chamber124. Such communication between evaporator170and ice making system200may be provided or enhanced by various air movers, such as a blower or fan180, connected to one or the other of supply duct172and return duct178. Supply duct172may include, for example, supply outlet174supplying cold air from freezer chamber124to an exterior portion of ice making system200. Return duct178may include, for example, return inlet176flowing air from ice making system200to freezer chamber124. Ducts172and178may generally be disposed within the refrigerator appliance100, such as within the various walls defining the chambers122,124. In some exemplary embodiments, the ducts172and178may be foamed in place within the various walls of the refrigerator appliance100.

The ice making system200may be in convective thermal communication with the freezer chamber124. In some embodiments, such convective thermal communication may be provided by the circulation system170which circulates cold air from the freezer chamber124to the ice making system200and in particular to a heat exchanger206thereof. In some embodiments, the heat exchanger206does not include or employ liquid refrigerant, the circulation of cold air alone cools the heat exchanger206.

In some exemplary embodiments, the ice maker200may include a mold body210configured for receiving liquid water and forming ice in the mold body210. The mold body210may be so configured by forming the mold body210with a series of impressions or recesses which receive liquid water therein and hold the liquid water at least until the liquid water freezes. In some exemplary embodiments, the ice maker200may include features for harvesting the ice from the mold body210once it has been formed, as well as features for storing and/or dispensing the harvested ice. In some exemplary embodiments, the mold body210may be in conductive thermal communication with the heat exchanger206to cool the mold body210and permit ice formation therein. Such conductive thermal communication may be provided in some exemplary embodiments by direct contact between the heat exchanger206and mold body210. In some exemplary embodiments, mold body210and heat exchanger206are formed of a material with a high thermal conductivity, e.g., a metal such as aluminum. In some embodiments, the heat exchanger206may be an extension of the mold body210, i.e., the mold body210and the heat exchanger206may be formed of a seamless one-piece unitary construction.

In some exemplary embodiments, the heat exchanger206may be in fluid communication with the freezer chamber124, while the ice making chamber202may not be in fluid communication with the freezer chamber124. In other words, the ice making chamber202may be isolated from the freezer chamber124such that cold air from the freezer chamber124does not flow into the ice making chamber202. Instead, in some exemplary embodiments, the cold air from the freezer chamber124may only flow around and through the heat exchanger206, and in particular between fins208thereof. In some exemplary embodiments, e.g., as shown inFIG. 5, the heat exchanger206extends through the insulation164at the heat exchange opening162. Therefore, in such exemplary embodiments, the heat exchanger206may be the only portion of the ice maker200not enclosed by the insulation164. In such embodiments, the outlet174and inlet176are positioned on wall123such that the outlet174and inlet176correspond or align with the heat exchange opening162when the door126is in the closed position, such that cold air may flow from outlet174, then downwardly along flow paths209(as described below) between fins208to inlet176. More particularly, in such exemplary embodiments, the outlet174may be positioned such that when the door126is in the closed position, the outlet174is proximate to an upper portion of the heat exchanger206and is surrounded by the gasket163, while the inlet176of return conduit178may be positioned below the outlet174of the supply conduit172such that when the door126is in the closed position the inlet176is proximate to a lower portion of the heat exchanger206and is surrounded by the gasket163.

In various exemplary embodiments, the heat exchanger fins208may be oriented along the vertical direction V. In such embodiments, vertical air flow paths209may be defined between adjacent fins208. In some exemplary embodiments, the vertical air flow paths209defined by the heat exchanger fins208are positioned within heat exchange opening162such that the air flow paths209extend between the outlet174of the supply conduit172and the inlet176of the return conduit178when the door126is in the closed position. In the exemplary embodiments illustrated herein, the fins208are continuous along the vertical extent of the heat exchanger206and are all parallel to one another. However, it is also possible within the scope of the present subject matter to provide fins208in various other configurations with vertical flow passages209therebetween. For example, individual fins208of the plurality of fins208may extend over less than the full vertical extent of the heat exchanger206and may be staggered with respect to one another. As another example, the fins208may be formed of separate rounded pieces, e.g., pins. Thus, it is to be understood that the fins208of the present subject matter are not limited to any particular shape and several possible variations thereof may be provided.

As may be seen, e.g., inFIGS. 6 and 7, in some exemplary embodiments, when the door126is in the closed position, the heat exchanger206defines a width along the transverse direction T. The width of the heat exchanger206may be substantially equal to a corresponding dimension of the heat exchange opening162. In some exemplary embodiments, the heat exchanger206may span the full extent of the heat exchange opening162across both a length and a width of the heat exchange opening162. Also, in some exemplary embodiments, fins208may extend away from a central body of the heat exchanger206, e.g., perpendicularly as illustrated for example inFIGS. 6 and 7. In other exemplary embodiments, fins208may be oblique to the central body. Fins208provide increased surface area for heat exchanger206, e.g., as compared to a flat surface of the central body without fins208, which may advantageously provide more rapid thermal energy transfer between chilled air from supply conduit172and heat exchanger206.

In some embodiments, a fan212may be provided in the ice making chamber. The fan212is operable to provide air circulation within the ice making chamber202and in particular over the mold body210. Such air circulation may be advantageous to assist in chilling the ice making chamber202and keeping the ice frozen. In particular, the ice making system200may be configured to operate fan212when the ice storage bin204is full and ice making is not required. In such embodiments, cold air may not be provided to the heat exchanger206from evaporator170when ice making is not required and therefore fan212may be activated when the storage bin204is full.