Active insulation hybrid dual evaporator with rotating fan

An appliance having a fresh food storage compartment and a freezer compartment. The appliance includes a forced air coil system disposed between the fresh food storage compartment and the freezer compartment and is configured to selectively provide cooling to one or both of the at least one fresh food storage compartment and the at least one freezer compartment. The forced air coil system includes an evaporator fan configured to provide cooling to the food storage compartment, the freezer compartment, or both.

FIELD OF THE INVENTION

The present invention generally relates to an appliance cooling system and a method for constructing therefore.

SUMMARY OF THE INVENTION

An aspect of the present invention is generally directed towards an appliance having an interior that includes a fresh food storage compartment and a freezer compartment separated by a mullion. The fresh food compartment has a direct cooling evaporator disposed in thermal communication with the fresh food storage compartment in order to provide cooling to the fresh food storage compartment. The freezer compartment includes a direct cooling evaporator disposed in thermal communication with the freezer compartment to provide cooling to the freezer compartment. The appliance further includes a forced air coil system disposed between the fresh food storage compartment and the freezer compartment. The forced air coil system is configured to selectively provide cooling to one or both of the fresh food storage compartment and the freezer compartment. The forced air coil system includes at least one turbo chilling evaporator and at least one moving evaporator fan which is operably and rotatably connected to the fresh food storage compartment and the freezer compartment.

Another aspect of the present invention is generally directed to an appliance cabinet having a food storage compartment, a freezer compartment, and a forced air coil system. The forced air coil system is in thermal communication and configured to provide cooling to the food storage compartment and the freezer compartment. Additionally, the forced air coil system is disposed within a cavity between the food storage compartment and the freezer compartment. The forced air coil system includes at least one turbo evaporator and at least one pivoting evaporator fan. The pivoting evaporator fan is operably and rotatably connected to be positioned in a first position which provides cooling to the food storage compartment and a second position which provides cooling to the freezer compartment.

Yet another aspect of the present invention is generally directed towards a method of providing cooling to a food storage compartment and a freezer compartment. An appliance cabinet includes a food storage compartment which receives cooling from the fresh food compartment evaporator and a freezer compartment which receives cooling from a freezer compartment evaporator and a forced air coil system disposed between the food storage compartment and the freezer compartment. Additionally, the forced air coil system is in air flow communication with both the food storage compartment and the freezer compartment. Moreover, the forced air coil system comprises a booster evaporator and an evaporator fan. Next, the evaporator fan is pivoted in a rotational motion to the first position in order to provide air flow to the fresh food storage compartment. Next the moisture is sublimated from the turbo evaporator and into the fresh food compartment in order to defrost the turbo evaporator. Next, the pivoting evaporator fan pivots in rotational motion to a second position which provides airflow to the freezer compartment. Finally, the evaporator fan can split its airflow between the at least one food storage compartment and the at least one freezer compartment.

DETAILED DESCRIPTION

The present invention is generally directed toward appliance systems and methods for increasing the efficiency (coefficient of performance) of the appliance. The appliance systems may be bottom mount freezer systems, top mount freezer systems, side by side refrigerator and freezer system, or French door style bottom mount freezer systems that may or may not employ a third compartment, typically a drawer that may operate as a refrigerator drawer or a freezer drawer.

The refrigerator2is adapted to receive and/or be capable of receiving a variety of shelves and modules at different positions defined by, in the embodiment shown inFIG. 1, a plurality of horizontally spaced vertical rails3extending from the rear wall4of the refrigerator and freezer cabinet sections or compartments16,18. In the embodiment shown, the supports are in the form of vertically extending rails3with vertically spaced slots for receiving mounting tabs on shelf supports7and similar tabs on modules, such as modules50(crisper),52(crisper),54(shelf unit), and56(drawer), for attaching the modules in cantilevered fashion to the cabinet sections16,18at selected incrementally located positions. The inside edges of doors8and9also include vertically spaced shelf supports, such as58, for positioning and engaging bins60and modules, such as62, in the doors, in particular within the pocket of the door defined by the liner64. The shelves, modules, bins, and the like, can be located at a variety of selected locations within the cabinet sections16,18and doors8,9to allow the consumer to select different locations for convenience of use.

Some of the modules in refrigerator2, such as modules50and62, may be powered modules or components and therefore require operating utilities. Thus, for example, module50may be a powered crisper or an instant thaw or chill module and may require utilities, such as cooled or heated fluids or electrical operating power and receive these utilities from the appliance. Other modules, such as module62, may likewise require operational utilities while modules, such as a passive crisper module, would not. Door modules also, such as module62, may, for example, include a water dispenser, vacuum bag sealer or other accessory conveniently accessible either from the outside of door8or from within the door and likewise may receive operating utilities from conduits, such as disclosed in application Ser. No. 12/469,915 filed May 21, 2009, entitled Refrigerator Module Mounting System; and Ser. No. 12/469,968 filed May 21, 2009, entitled Multiple Utility Ribbon Cable. The disclosures of these patent applications are incorporated herein by reference in their entirety. While not shown in the figures, the modules may also be used for quick cooling of beverages, quick freezing/chilling of other food stuffs or even making of ice, ice pieces (cubes), or frozen products.

The present invention includes the use of sequential dual evaporator systems that employ a switching mechanism. The switching mechanism allows the system to better match total thermal loads with the cooling capacities provided by the compressor. Generally speaking, the appliance gains efficiency by employing the switching mechanism, which allows selection of the evaporator circuit to be fed refrigerant with a liquid line valving system resulting in independent fresh food and freezer cooling cycles of several (>4) minutes duration or via a rapid suction port switching, typically on the order of a fraction of a second. The suction side switching mechanism can be switched at a fast pace, typically about 30 seconds or less or exactly 30 seconds or less, more typically about 0.5 seconds or less or exactly 0.5 seconds or less, and most typically about 10 milliseconds or less or exactly 10 milliseconds or less (or any time interval from about 30 seconds or less). As a result, the system rapidly switches between a freezer compartment operation mode and a refrigeration (fresh food) operation mode. The compressor12may be a variable capacity compressor, such as a linear compressor, in particular an oil-less linear compressor, which is an orientation flexible compressor (i.e., it operates in any orientation not just a standard upright position, but also a vertical position and an inverted position, for example). The compressor is typically a dual suction compressor or a single suction compressor with an external switching mechanism. When the compressor is a single suction compressor, it typically provides non-simultaneous dual suction from the coolant fluid conduits20from the refrigeration (fresh food) compartment and the freezer compartment.

As discussed above and shown generally inFIG. 2, the coolant system10utilized according to an aspect of the present invention typically includes a compressor12operably connected to at least one evaporator14where the compressor is typically the only compressor associated with the appliance for regulating the temperature of the first compartment16(typically the fresh food compartment) and the temperature of a second compartment18(typically the freezer compartment). The coolant system also typically employs: fluid conduits20; at least one condenser22, but typically a single condenser; a filter/dryer24; and one or more expansion devices26, such as a capillary tube or capillary tubes. The coolant system may also optionally employ one or more check valves28that prevent back flow of coolant fluid in the overall coolant system in the lower pressure fluid conduit. Check valves are typically employed when a multiple evaporator coolant system is employed operating in a non-simultaneous manner with different evaporating pressures. The check valve being incorporated into the lower pressure suction line.

As shown inFIG. 2, one aspect of the present invention utilizes a sequential, dual evaporator refrigeration system as the coolant system10. The dual evaporator refrigeration system shown inFIG. 2employs two evaporators14fed by two fluid conduits20engaged to two separate expansion devices26.

As discussed above, the first compartment is typically the refrigeration or fresh food compartment. The second is typically the freezer compartment. While this is the typical configuration, the configuration could conceivably be two refrigeration compartments or two freezer compartments.

As shown in various figures, includingFIGS. 8-10, the appliance may be any of the known configurations for a refrigeration appliance typically employed such as side by side, top mount freezer, bottom mount freezer or French door bottom mount freezer. Generally speaking, each of the embodiments employ at least two compartments, a first compartment16, which is typically a fresh food compartment or a compartment operating at a higher operating temperature than a second compartment18, which is typically a freezer compartment. Also, generally speaking each compartment has its own evaporator14associated with it. For example, while two evaporators are typically employed (one for the fresh food compartment and the other for the freezer compartment) a third may be used and associated with an optional third drawer. Fluid conduits20provide fluid flow from the compressor to at least one condenser22, through a filter/dryer24(when utilized), through at least one expansion device26such as a capillary tube or tubes, and to at least one evaporator14, more typically multiple evaporators. Ultimately, fluid is returned to the compressor12. Fans28, which are optional, are generally positioned proximate the evaporator(s) to facilitate cooling of the compartment/heat transfer. Similarly, fans28may be used in conjunction with the condenser22(seeFIG. 10). Typically, fans improve heat transfer effectiveness, but are not necessary.

In the case of the top mount and bottom mount freezer, the mullion separating the compartments is typically a horizontal mullion. In the case of a side by side configuration, the mullion separating the two compartments is a vertical mullion.

The compressor12may be a standard reciprocating or rotary compressor, a variable capacity compressor, including but not limited to a linear compressor, or a multiple intake compressor system. When a standard reciprocating or rotary compressor with a single suction port is used the system further includes a compressor system30(not shown in figures). A compressor according to an aspect of the present invention may utilize a compressor system40that contains two coolant fluid intake streams such as one from the refrigerator compartment evaporator and one freezer compartment evaporator. When a linear compressor, which can be on oil less linear compressor, is utilized, the linear compressor has a variable capacity modulation, which is typically larger than a 3 to 1modulation capacity typical with a variable capacity reciprocating compressor. The modulation low end is limited by lubrication and modulation scheme.

Thermal storage material may also be used to further enhance efficiencies of the appliance. Thermal storage material46(FIG. 9), which can include phase changing material or high heat capacity material or high heat capacity material such as metal solids can be operably connected to the first compartment evaporator. The thermal storage material may be in thermal contact or engagement with the first compartment evaporator, in thermal contact or engagement with the fluid conduit(s)20operably connected to the first compartment evaporator, or in thermal contact or engagement with both. The use of the thermal storage material helps prevent relatively short relatively short “down” time of the compressor12. Similarly, a thermal storage material can be associated with the second evaporator/compartment. Additionally, the second compartment may have vacuum insulation panels48insulating it to further improve the efficiency of the system by driving more of the thermal load to the first compartment.

One aspect of the present invention, shown inFIGS. 3-7includes a forced air coil system100which is disposed in the mullion between the food storage compartment16and the freezer compartment18. The forced air coil system100is configured to provide cooling to one or both of the fresh food storage compartment16and the freezer compartment18. Additionally, the forced air coil system100includes at least one turbo chilling evaporator102, which typically does not have evaporator fins, and at least one moving evaporator fan104which is operably and rotatably connected to the fresh food storage compartment16and the freezer compartment18. As shown inFIGS. 5-7, the evaporator fan104is configured to move between at least a first position106(FIG. 6), a second position108(FIG. 7), and a third position110(FIG. 5). The pivoting evaporator fan104generally rotates in rotational motion using a semi-circular carriage, typically driven by an actuator such as a synchronous motor with the ability to operate in a clockwise and a counter-clockwise rotation. When the pivoting evaporator fan104is in the first position106, it is configured to provide cooling or fast recovery cooling to the fresh food storage compartment16. When the evaporator fan104is in the second position108, the forced air coil system100is configured to provide cooling to the freezer compartment18. Moreover, when the evaporator fan104is in the third position110, the forced air coil system100is configured to provide cooling to both the fresh food storage compartment16and the freezer compartment18. Additionally, the fan carriage via linkages can drive sliding air doors (not shown) for covering the compartment air inlets and diffusers to forced air coil system100, thus selectively isolating forced air coil system100from thermal convection communication with the respective fresh food or freezer compartments. An air flow separator102′ (FIG. 3) incorporated into the turbo chilling coil102can be employed to allow the respective compartment air return to be located adjacent the evaporator fan104discharge diffusers without allowing the return inlet air to short circuit to the fan within forced air coil system100. Additionally this air flow separator102′ can be straight section or stari stepped as shown. If stair stepped, the separator serves to accelerate the air flow over the evaporator surface and thus enhances heat transfer between evaporator coil and air stream. The evaporator fan104is connected to a central unit60and temperature sensors114(shown inFIG. 8), typically employing a CPU which provides logic for driving operations of compressor, valves, fans, fan carriage positioning, and temperature sensing.

The forced air coil system100uses input from the sensors114and a user set point in order to determine when to deliver the turbo chilling to the fresh food compartment16, the freezer compartment18, or both. The forced air coil system100is configured to provide shock freezer capability dehumidification or fast recovery for the fresh food compartment16and the freezer compartment18. Significantly, by having the forced air coil system100outside of the freezer compartment18and the fresh food storage compartment16, the turbo evaporator coil102can be defrosted without heating up either the food storage compartment16or the freezer compartment18.

The refrigerator may also include a variable capacity compressor12, a condenser22, at least two valves and cooling conduits20that are configured to operably deliver coolant to and from the condenser22. Further, the appliance may include a direct cooling evaporator14in the fresh food compartment16, a direct cooling evaporator14in the freezer compartment18and at least one turbo evaporator102. Additionally, a common refrigerant coolant conduit section20is the only coolant outlet from the compressor12. Moreover, the condenser22can be the only condenser22that supplies coolant to the fresh food compartment direct cooling evaporator14, the freezer compartment direct cooling evaporator14, and the turbo chilling evaporator102. The coolant leaves each of the evaporators14and merges into a shared coolant flow either within the compressor12or after the coolant passes through the evaporators14, but before entering the compressor12. In this case, the compressor12is the only compressor12that supplies coolant to the condenser22. The compressor12may also be at least a triple suction compressor with a first port suction receiving coolant from the fresh food compartment direct cooling evaporator14, a second port suction receiving coolant from the freezer compartment direct cooling evaporator14and a third port suction receiving coolant from the turbo chilling evaporator102. Further, the variable capacity compressor12can be a linear compressor.

FIGS. 8-10show different refrigerator configurations each having the forced air coil system100of the present invention. The cooling systems may be incorporated into a variety of appliance configurations, including a bottom mount freezer system, a top mount freezer system, a side by side configuration, and a French door configuration that may or may not further include an optional third drawer that may function as either a freezer or a refrigerator (fresh food) compartment.

The forced air coil system100of the present invention helps maintain either the fresh food storage compartment, or the freezer compartment, or both at a steady temperature in order to optimize food preservation. Additionally, the forced air coil system100of the present invention is capable of providing shock freeze capability or ultra-fast recovery for better freezer storage life. Moreover, as discussed above, placing the forced air coil system100in the mullion of the appliance, allows the evaporator coil of the forced air coil system100to heat up without heating up the freezer compartment or the fresh food storage compartment of the appliance.