Methods and apparatus for operating a refrigerator

A method for operating a refrigerator including a fresh food compartment and a door includes providing a fresh food evaporator to produce cool airflow for the fresh food compartment, providing a chiller compartment within the fresh food compartment, providing a duct member in flow communication with the fresh food evaporator and the chiller compartment, and channeling cool airflow to the chiller compartment via the duct member.

BACKGROUND OF THE INVENTION

This invention relates generally to methods and apparatus for operating a refrigerator, and more particularly, to methods and apparatus for operating a refrigerator having a chiller compartment.

A typical household refrigerator includes a freezer storage compartment and a fresh food storage compartment either arranged side-by-side or separated by a center mullion wall or over-and-under and separated by a horizontal center mullion wall. Shelves and drawers typically are provided in the fresh food compartment, and shelves and wire baskets typically are provided in the freezer compartment. In addition, an ice maker may be provided in the freezer compartment. A freezer door and a fresh food door close the access openings to the freezer and fresh food compartments, respectively.

Known refrigerators typically require extended periods of time to cool food and beverages placed therein. For example, it typically takes about four hours to cool a six pack of soda to a temperature of about 45° Fahrenheit (“F”). Beverages, such as soda, are often desired to be chilled in much less time than several hours. Thus, occasionally these items are placed in a freezer compartment for rapid cooling. If not closely monitored, the items will freeze and possibly break the packaging enclosing the item and creating a mess in the freezer compartment.

Numerous quick chill and super cool compartments located in refrigerator fresh food storage compartments and freezer compartments have been proposed to more rapidly chill and/or maintain food and beverage items at desired controlled temperatures for long term storage. Conventional compartments generally have duct systems attracting cold air from the freezer compartments, and utilize an existing freezer fan to channel cold air into the compartments. As a result, food or beverage items placed in chill compartments are susceptible to undesirable freezing if too much cold air is drawn from the freezer compartment into the chill compartment. Moreover, the duct systems may become frozen if moist air is input into the duct system and then cooled. In addition, conventional chill compartments may undesirably reduce refrigerator compartment space.

Accordingly, it would be desirable to provide a refrigerator having a quick chill compartment located within the fresh food compartment wherein the quick chill compartment maintains a colder temperature than the fresh food compartment and the quick chill compartment is always above freezing.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a method for operating a refrigerator including a fresh food compartment and a door is provided. The method includes providing a fresh food evaporator to produce cool airflow for the fresh food compartment, providing a chiller compartment within the fresh food compartment, providing a duct member in flow communication with the fresh food evaporator and the chiller compartment, and channeling cool airflow to the chiller compartment via the duct member.

In another aspect, a refrigerator is provided including a fresh food compartment, and a fresh food evaporator in flow communication with the fresh food compartment and producing cool airflow therein. The refrigerator also includes a chiller compartment positioned within the fresh food compartment, and a duct member configured to transmit cool airflow from the fresh food evaporator into the chiller compartment.

In yet another aspect, a chiller compartment is provided for use with a refrigerator including a fresh food compartment, and a fresh food evaporator. The chiller compartment includes an enclosure defining a cavity configured to receive refrigerated items therein, and an inlet extending through the enclosure. The inlet is configured to receive cooling air from the fresh food evaporator such that the chiller compartment operates at a temperature below the operating temperature in the fresh food compartment.

In a further aspect, a chiller compartment assembly is provided for use with a refrigerator including a refrigerator door having an inner liner, a fresh food compartment, and a fresh food evaporator. The chiller compartment assembly includes an enclosure defining a cavity configured to receive refrigerated items therein. The chiller compartment assembly also includes at least one positioning element extending from an exterior surface of the enclosure, and a door insert configured to be coupled to the inner liner of the refrigerator door. The door insert includes at least one shoulder extending from an interior surface of the door insert, and the shoulder is configured to engage the positioning element.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1illustrates an exemplary side-by-side refrigerator100in which the present invention may be practiced. It is recognized, however, that the benefits of the present invention may be accrue to types of refrigerators, and consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect. Refrigerator100includes a fresh food (FF) compartment102and freezer (FZ) compartment104which are divided by a center mullion114. In the exemplary embodiment, freezer compartment104and fresh food compartment102are arranged side-by-side. In an alternative embodiment, freezer compartment104and fresh food compartment102are arranged in a top and bottom arrangement.

In the exemplary embodiment, a temperature control118is positioned within FF compartment102for setting a desired temperature for the FF compartment102and/or the FZ compartment104. Additionally, a temperature sensor116is positioned within FF compartment102for determining the temperature of the air within FF compartment102. In one embodiment, temperature sensor116is a resistance temperature detector (RTD) to detect the temperature of FF compartment102, and to ensure that the temperature in FF compartment102remains within predetermined limits, such as, but not limited to, a set range of, for example, within approximately 5-10° F. of the set temperature. In the exemplary embodiment, temperature sensor116is operatively coupled to a controller (not shown), such as, for example, a microprocessor, for controlling the temperature of FF compartment.

Refrigerator100includes an outer case106and an inner liner108. The space between case106and liner108is filled with an insulating material, such as, but not limited to, a foamed-in-place insulation. Additionally, the space within mullion114is filled with an insulating material, such as, but not limited to, a foamed-in-place insulation. Outer case106is normally formed by folding a sheet of a suitable material, such as pre-painted steel, into an inverted U-shape to form top and sidewalls of case106. A bottom wall of case106is normally formed separately and attached to the case sidewalls and to a bottom frame (not shown) that provides support for refrigerator100. Inner liner108is molded from a suitable plastic material to form freezer compartment104and fresh food compartment102, respectively. Alternatively, liner108may be formed by bending and welding a sheet of a suitable metal, such as steel.

A rotatable door110closes access openings to fresh food compartment102. Door110is mounted by a top hinge112and a bottom hinge (not shown) to rotate about its outer vertical edge between an open position, as shown inFIG. 1, and a closed position (not shown) closing the fresh food storage compartment102. An inner liner (not shown) is generally mounted within rotatable door110. The inner liner is generally made of plastic materials. The space between door110and the inner liner is also filled with foamed materials to better maintain the temperature in refrigerator100.

In the exemplary embodiment, a chiller compartment120is located within rotatable door110. During operation of the refrigerator100, chiller compartment120is configured to be operated at a temperature that is different than FF compartment102temperature, but above the freezing temperature. Specifically, chiller compartment120is operated at a lower temperature than FF compartment102to facilitate chilling refrigerated items such as, but not limited to, beverages. Chiller compartment120operates as a quick chill compartment to chill refrigerated items more quickly than if the items were placed directly into the FF compartment102, and without the risk of freezing. In the exemplary embodiment, chiller compartment120is fabricated from a material such as, for example, a plastic material. Moreover, in the exemplary embodiment, chiller compartment120includes an air inlet122formed in a sidewall126of chiller compartment120for injecting cool air into chiller compartment120. Additionally, in one embodiment, an air outlet124is formed in chiller compartment120for expelling cool air therefrom.

FIG. 2is a partial cutaway view of a rear portion of refrigerator100illustrating a FF cooling system130. In the exemplary embodiment, FF cooling system130includes a FF evaporator132positioned at a backside of refrigerator100for producing cool air for FF cooling system130. FF cooling system130also includes a FF fan134positioned in an airflow path136of FF cooling system130for channeling cool air into FF storage compartment102(shown inFIG. 1). In one embodiment, FF cooling system130includes an evaporator temperature sensor138, such as, for example, a thermistor, for determining the temperature of coolant in evaporator132.

In the exemplary embodiment, FF cooling system130also includes a chiller compartment cooling sub-system140for cooling chiller compartment120(shown inFIG. 1). Specifically, a divider142, made of an insulating material, such as, but not limited to, an expanded polystyrene (EPS) material, is positioned adjacent to FF evaporator132and FF fan134. Divider142includes an inlet144for allowing passage of a portion of the cool air produced by FF evaporator132to be channeled into chiller compartment cooling sub-system140. In one embodiment, chiller compartment cooling sub-system140includes a fan146positioned within inlet144of divider142. In one embodiment, fan146is a variable speed fan. Fan146facilitates channeling cool air through chiller compartment cooling sub-system140. In the exemplary embodiment, an electric motor (not shown) drives fan146and is operatively coupled to a controller (not shown), such as, for example, a microprocessor (not shown), for controlling the amount of cool air channeled into sub-system140. The airflow from fan146is channeled through a duct150that extends through mullion114(shown inFIG. 1) between FF storage compartment102and freezer storage compartment104. In one embodiment, sub-system140includes a reducer152having a transition section that is connected between fan146and duct150.

In one embodiment, FF cooling system130also includes a heater153coupled to duct150. Heater153facilitates reducing moisture within duct150, thus reducing a risk of freezing within duct150. Additionally, heater153facilitates preventing icing within and around duct150. In another embodiment, heater153is utilized to defrost duct150.

Returning toFIG. 1, duct150includes an outlet154extending through mullion114into FF compartment102. Outlet154is oriented such that duct150is in flow communication with air inlet122of chiller compartment120when door110is in the closed position. As such, cool air produced by FF evaporator132(shown inFIG. 2) is channeled to chiller compartment120via duct150.

FIG. 3is a flow diagram of the operation of chiller compartment cooling sub-system140. Specifically, refrigerator100includes a controller156, such as, for example, a microprocessor. Controller156receives a plurality of inputs. Specifically, in the exemplary embodiment, controller156receives an input from temperature control118(FIG. 1) relating to a user entered set temperature. Additionally, controller156receives an input from FF compartment temperature sensor116(FIG. 1) relating to the temperature of the air in FF compartment102. Moreover, controller156receives an input from FF evaporator temperature sensor138(FIG. 2) relating to the temperature of the coolant in evaporator132. In one embodiment, controller156also receives an input158relating to a freezing limit of the cooling air supplied to chiller compartment cooling sub-system140(FIG. 2). Specifically, the freezing limit input causes controller156to cease operation when cooling sub-system140is approaching the freezing limit. As such, controller156facilitates reducing the risk of freezing in cooling sub-system140. In an alternative embodiment, controller156receives an input from a temperature sensor (not shown) positioned within chiller compartment120(FIG. 1) relating to the temperature of the air in chiller compartment120.

In the exemplary embodiment, controller156is operatively coupled to chiller compartment fan146. As such, controller156determines a mode of operation of chiller compartment fan146based on the inputs received by controller156. In one embodiment chiller compartment fan146operates in either an “ON” or an “OFF” mode of operation. In another embodiment, chiller compartment fan146is a variable speed fan and operates at multiple speeds. In one embodiment, controller156may also be operatively coupled to FF fan134.

FIG. 4is an exploded perspective view of chiller compartment120including a front panel200, a back panel202, and a side panel204which are assembled together to form a compartment for refrigerated items. Optionally, the items may be stored at a lower temperature that other items that are stored in FF compartment102. In an alternative embodiment, front panel200, back panel202, and side panel204are unitarily formed. Optionally, chiller compartment120includes shelves206. Front panel200includes a top member214, a bottom member216, and a pair of side members212connected between top and bottom members214and216. In the exemplary embodiment, apertures218are formed in both top and bottom members214and216proximate one side member212. Specifically, an upward facing aperture218is formed in bottom member216generally vertically below and substantially aligned with a downward facing aperture218in top member214. Apertures218are configured to receive a chiller compartment door220.

Chiller compartment door220covers a cavity222defined by front and back panels200and202, respectively. Door220includes a pair of projections224extending outwardly from a top side226and a bottom side228of door220. Projections224are oriented for insertion into corresponding apertures218of front panel200. A biasing member230, such as, for example, a bias spring232, is positioned between projections224and apertures218. In operation, when a user opens chiller compartment door220to access chiller compartment120, biasing member230provides a biasing force on door220to retain door220in an open position. As such, biasing member230facilitates accessing chiller compartment120without a user having to hold chiller compartment door220in an open position because door220remains in the open position by the biasing force.

In one embodiment, biasing member230retains door220in an open position that is substantially orthogonal with respect to front panel200. In another embodiment, biasing member230retains door220in an open position that is approximately 110° with respect to front panel200. As such, the user can close refrigerator door110without chiller compartment door220interfering with mullion114(shown inFIG. 1). Accordingly, biasing member230facilitates reducing the risk of door220jamming with mullion114. In an alternative embodiment, biasing member230exerts a closing force on chiller compartment door220such that door220is closed when not forced open by the user.

In the exemplary embodiment, a latch mechanism234is coupled to chiller compartment door220and engages with side panel204to retain door220in a closed position. Specifically, an opening236is defined in a distal side238of chiller compartment door220and latch mechanism234is positioned within opening236. In the exemplary embodiment, latch mechanism234is received in opening236and an elastic latch button240is engaged with latch mechanism234. In the exemplary embodiment, latch button240releases latch mechanism234from side panel204such that chiller compartment door220may be opened.

FIG. 5is an exploded, perspective view of a door insert300provided to couple chiller compartment120to refrigerator door110. Door insert300has a “U” shape and is made of a rigid material such as, for example, a plastic material or a metal material. Door insert300includes opposite sidewalls302and a back wall304connected therebetween. A shoulder306is located on an inner surface308of each sidewall302. A positioning member310is located on an outer surface312of each sidewall302. A plurality of support members314extends from an inner liner316of door110for positioning door insert300within door110. Specifically, support members314are oriented at different positions along inner liner316such that door insert300may be coupled to inner liner316of refrigerator door110at multiple positions.

In the exemplary embodiment, chiller compartment120has at least one positioning element318formed on each side thereof. Positioning elements318are oriented to be coupled to corresponding shoulders306extending from door insert inner surfaces308. Specifically, chiller compartment120has a width that is less than the width of door insert300such that chiller compartment120can be positioned within door insert300. In assembly, door insert300is positioned within door110such that positioning member310is substantially aligned with a corresponding support member314prior to being coupled thereto. Once coupled at a predetermined position, chiller compartment120is positioned within door insert300such that positioning elements318are substantially aligned with corresponding shoulders306prior to being coupled thereto. Positioning elements318engage shoulders306by moving chiller compartment120along a generally vertical path of movement. Due to the multiple positions available for door insert300to be coupled in refrigerator door110, chiller compartment is useable with different sized FF liners316. Alternatively, refrigerator door110is capable of receiving multiple sized chiller compartments120.

A refrigerator having a chiller compartment is thus obtained by modulating a FF fan at the FF evaporator to direct cool air from the FF evaporator to the chiller compartment. As such, the chiller compartment is not cooled by air from a FZ compartment, thus reducing the risk of freezing the duct supplying air and the refrigerated items in the chiller compartment.