Ice maker air flow ribs

A refrigeration appliance includes a freezer compartment for storing food items. An ice maker is disposed within the freezer compartment and includes a removable ice bin having an internal cavity. A front cover closes a front open end of the ice bin. The front cover includes a front face oriented toward a front of the freezer compartment, a rear face, and a recess formed in the rear face. The rear face of the front cover is disposed adjacent to a horizontal edge portion of the ice maker when the removable ice bin is disposed within the ice maker wherein the recess defines a gap between the front cover and the horizontal edge portion that fluidly communicates with the internal cavity of the removable ice bin. A plurality of ribs is disposed within the gap for directing air exiting the internal cavity of the removable ice bin into a predetermined direction.

FIELD OF THE INVENTION

This application relates generally to an ice maker for a refrigeration appliance, and more particularly, to a refrigeration appliance including an ice maker disposed within a freezer compartment of a refrigerator that is maintained at a temperature below a freezing temperature of water at atmospheric conditions.

BACKGROUND OF THE INVENTION

Conventional side-by-side refrigeration appliances, such as domestic refrigerators, require a large space in an upper portion of a freezer compartment for an ice maker. The large size of the ice maker reduces that amount of storage available to a user. In instances where the ice maker does not contact both sides of the freezer compartment, the ice maker only leaves enough space for one or two long, narrow packages, e.g., pizza boxes.

Accordingly, there is a need in the art for a refrigerator including an ice maker disposed within a freezer compartment of the refrigerator that creates an enlarged space laterally of the ice making unit for increased food storage while still providing for efficient cooling of the freezer compartment.

BRIEF SUMMARY OF THE INVENTION

In accordance with one aspect, there is provided a refrigeration appliance that includes a freezer compartment for storing food items in a sub-freezing environment having a target temperature below zero degrees Centigrade. An ice maker is disposed within the freezer compartment for freezing water into ice pieces. The ice maker includes a removable ice bin having an internal cavity for storing the ice pieces produced within the ice maker, and a front cover for closing a front open end of the removable ice bin. The front cover includes a front face oriented toward a front of the freezer compartment, a rear face, and a recess formed in the rear face. The rear face of the front cover is disposed adjacent to a horizontal edge portion of the ice maker when the removable ice bin is disposed within the ice maker wherein the recess in the front cover defines a gap between the front cover and the horizontal edge portion that fluidly communicates with the internal cavity of the removable ice bin. A plurality of ribs is disposed within the gap for directing air exiting the internal cavity of the removable ice bin into a predetermined direction toward a central portion of the freezer compartment.

In accordance with another aspect, there is provided a refrigeration appliance that includes a freezer compartment for storing food items in a sub-freezing environment having a target temperature below zero degrees Centigrade. An ice maker is disposed within the freezer compartment for freezing water into ice pieces. The ice maker includes a frame having a horizontal edge portion, a removable ice bin having an internal cavity for storing the ice pieces produced within the ice maker, and a front cover for closing a front open end of the removable ice bin. The front cover includes a front face oriented toward a front of the freezer compartment, a rear face, and a recess formed in the rear face. The rear face of the front cover is disposed adjacent to the horizontal edge portion of the frame when the removable ice bin is disposed within the frame wherein the recess in the front cover defines a gap between the frame and the removable ice bin that fluidly communicates with the internal cavity of the removable ice bin. A plurality of ribs is disposed within the gap for directing air exiting the internal cavity of the removable ice bin into a predetermined direction toward a central portion of the freezer compartment.

In accordance with yet another aspect, there is provided a refrigeration appliance that includes a freezer compartment for storing food items in a sub-freezing environment having a target temperature below zero degrees Centigrade. An ice maker is disposed within the freezer compartment for freezing water into ice pieces. The ice maker includes a removable ice bin that includes a housing having an internal cavity for storing the ice pieces produced within the ice maker and a horizontal edge portion. A front cover is provided for closing a front open end of the housing. The front cover includes a front face oriented toward a front of the freezer compartment, a rear face, and a recess formed in the rear face. The rear face of the front cover is disposed adjacent to the horizontal edge portion of the housing wherein the recess in the front cover defines a gap between the front cover and the housing that fluidly communicates with the internal cavity of the housing. A plurality of ribs is disposed within the gap for directing air exiting the internal cavity of the housing into a predetermined direction toward a central portion of the freezer compartment.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Referring now to the drawings,FIG. 1shows a typical household refrigerator10comprising a fresh food compartment12and a freezer compartment14. A door16, shown inFIG. 1as open, is mounted to the refrigerator body by hinges and serves to close the front of the fresh food compartment12as well as provide access to the interior of the fresh food compartment12. A door18is mounted to the refrigerator body by hinges and serves to close the front of the freezer compartment14as well as provide access to the interior of the freezer compartment14. The fresh food and freezer compartments12,14may include a variety of shelves22, closed drawers24and basket-like drawers26for storing articles of food and the like.

A dispenser (not shown) for dispensing at least ice pieces, and optionally water, is provided on door18. The dispenser includes a lever, switch, proximity sensor or other device that a user can interact with to cause frozen ice pieces to be dispensed from an ice maker50disposed within the freezer compartment14through the door18. Ice pieces from the ice maker50can be delivered to the dispenser via an ice chute28, which extends at least partially through the door18between the dispenser and the ice bin52.

The fresh food compartment12serves to minimize spoiling of articles of food stored therein by maintaining the temperature in the fresh food compartment12during operation at a cool temperature that is typically less than an ambient temperature of the refrigerator10, but somewhat above 0° C., so as not to freeze the articles of food in the fresh food compartment12. An evaporator is used to separately maintain the temperature within the fresh food compartment12independent of the freezer compartment14. According to an embodiment, the temperature in the fresh food compartment12can be maintained at a cool temperature within a close tolerance of a range between 0° C. and 4.5° C., including any subranges and any individual temperatures falling with that range. For example, other embodiments can optionally maintain the cool temperature within the fresh food compartment12within a reasonably close tolerance of a temperature between 0.25° C. and 4° C.

The freezer compartment14is used to freeze and/or maintain articles of food stored in the freezer compartment14in a frozen condition. For this purpose, an evaporator (not shown) provides a cooling effect to the freezer compartment14. The evaporator is supported within the freezer compartment14, and an electric fan (not shown) is located adjacent to the evaporator. Operation of the electric fan draws the airflow upward over the fins and coils of the evaporator, and then in a forward direction, generally parallel to the ceiling portion of the freezer compartment14and toward a front of the freezer compartment14, as described in detail below.

The evaporator also reduces a temperature of the air within the ice maker50(FIG. 2) for freezing water into the ice pieces and for maintaining a temperature in an ice bin52of the ice maker50. In one example, the refrigeration circuit includes a variable-speed compressor for compressing gaseous refrigerant to a high-pressure refrigerant gas. The compressor can optionally be infinitely variable, or can be varied between a plurality of predetermined, discrete operational speeds depending on the demand for cooling. The high-pressure refrigerant gas from the compressor can be conveyed through a suitable conduit such as a copper tube to a condenser, which cools the high-pressure refrigerant gas and causes it to at least partially condense into a liquid refrigerant.

An illustrative embodiment of the ice maker50is shown inFIG. 2. In general, the ice maker50includes a frame54and an ice bin52that stores ice pieces made by the ice maker50. The ice maker50is secured within the freezer compartment14using any suitable fastener. The frame54is generally rectangular in shape for receiving the ice bin52. A plurality of mounts56is disposed on a top of the frame54for securing the ice maker50within the freezer compartment14of the refrigerator10. A rectangular side opening55is formed in an upper portion of a side wall of the frame54of the ice maker50. The side opening55is positioned to be adjacent to or in registry with a space above an ice tray62disposed within the ice maker50. The ice bin52is dimensioned to be selectively removable from the frame54, as desired.

The ice bin52includes a housing53having an open, front end and an open top. A front cover58is secured to a front of the housing53to enclose the open, front end of the housing53. When secured together to form the ice bin52, the housing53and the front cover58define an internal cavity52a(FIG. 4) of the ice bin52used to store the ice pieces. The front cover58may be secured to the housing53by mechanical fasteners that can be removed using a suitable tool, examples of which include screws, nuts and bolts, or any suitable friction fitting possibly including a system of tabs allowing removal of the front cover58from the housing53by hand and without tools. Alternatively, the front cover58is non-removably secured in place on the housing53using methods such as, but not limited to, adhesives, welding, non-removable fasteners, etc. In various other examples, a hidden latch to secure the ice bin52in frame54is desirable on the front cover58for cosmetic and ergonomic reasons. The frame54includes a horizontal plate portion57that is dimensioned to close a portion of the open top of the housing53of the ice bin52when the ice bin52is disposed in the frame54. The horizontal plate portion57includes a front horizontal edge57athat is dimensioned to engage the front cover58of the ice bin52.

Referring now toFIG. 7, an ice tray62is positioned in an upper portion of the ice maker50. In one example, the ice tray62is a twist-tray type, in which the ice tray62is rotated upside down and twisted along its longitudinal axis to thereby break the frozen ice pieces free from the ice reservoirs of the ice tray62where they fall into the internal cavity52aof the ice bin52located below the ice tray62. Still, a conventional metal water tray with a plurality of sweeper-arms and a harvest heater for partially melting the ice pieces, or even other types of ice maker assemblies like the finger-evaporator type, could also be utilized.

For simplicity, many of the internal components of the ice maker50are not shown in the present application. A main inlet channel64extends through a back of the frame54of the ice maker50. The channel64defines an air inlet pathway “A” of the ice maker50. The channel64divides into a first branch64athat fluidly communicates with the space above the ice tray62and a second branch64bthat fluidly communicates with the underside of the ice tray62and the internal cavity52aof the ice bin52. A channel66is formed in the frame54at a front of the ice tray62. The channel66fluidly connects the space above the ice tray62with the internal cavity52aof the ice bin52. The first branch64a, the space above the ice tray62and the channel66define an upper air pathway “B” of the ice maker50. The second branch64b, the space below the ice tray62, and in the internal cavity52adefine a lower air pathway “C” of the ice maker50.

As shown inFIG. 7, the front cover58encloses a front open end of the housing53of the ice bin52. The front cover58includes a lower channel72for allowing the ice pieces to exit the internal cavity52aof the ice bin52. The lower channel72is dimensioned and positioned to be in registry with an aperture28aof the ice chute28in the door18when the door18is in the closed position. The lower channel72defines an ice piece exit pathway “D” for conveying ice pieces from the internal cavity52aof the ice bin52.

A rotatable auger (not shown) is positioned within the ice bin52and is configured to drive the ice pieces out of the ice bin52via a driving force applied in a first direction. In particular, the auger is rotated to push the ice pieces toward the front of the ice bin52(i.e., towards the front cover58) wherein an ice crusher (not shown) is disposed. The ice crusher is provided for crushing the ice pieces conveyed thereto, when a user requests crushed ice.

As noted above, there is a need for an ice maker that creates an enlarged space laterally of the ice maker for increased food storage while still providing for efficient cooling of the freezer compartment. To increase the cooling efficiency in the freezer compartment, the circulation of the cooling air in the freezer compartment can be increased by improving the flow characteristics of the cooling air emitted by the ice maker. In particular, an ice maker that improves the circulation of cooling air to a central interior portion of a freezer compartment, i.e., away from corner(s) of the freezer compartment, is desired.

In the embodiment shown inFIG. 3, a plurality of ribs82are disposed in a recess84formed in an upper end of the back surface of the front cover58. The ribs82are flat planar elements that are disposed at an angle relative to a horizontal plane. In particular, the ribs82are disposed at an angle θ that is less than 90 degrees. It is also contemplated that the ribs82may be curved (ribs82ainFIG. 3) or of various lengths and orientations so as to obtain the desired flow characteristics for the cooling air exiting the ice maker50. For example, some of the ribs82may be oriented in a first direction whereas other ribs82may be oriented in a second, different direction. However, if a more laminar (i.e., less turbulent) air flow is desired out of the ice maker50, some (including a majority) or all of the ribs82may be aligned, such as at substantially the same angle, thereby increasing the airflow efficiency in the freezer compartment14.

In the embodiment shown, the ribs82have a fixed orientation. It is contemplated that the ribs82may be adjustable by an operator to achieve a desired flow characteristic. For example, one or more of the ribs82can be pivotal such that the angle of the one or more ribs82relative to a horizontal plane can be individually or collectively varied. Once the desired orientation of the one or more ribs82is obtained, the ribs82can be locked into that orientation to prevent a user from changing the orientation of the ribs82at a later time.

In the embodiment shown, the ribs82are attached to the front cover58. It is contemplated that all or some of the ribs82may be formed in the front horizontal edge57aof the frame54at a location opposite the recess84in the front cover58. For example,FIG. 2shows a plurality of ribs82B disposed in a recess84B formed in the frame54. It is also contemplated that one or more of the ribs82may be split between the front cover58and the frame54. For example, a first portion of at least one rib82may be formed in the front cover58and a remaining second portion of the at least one rib82may be formed in the front horizontal edge57aof the frame54. Some or all of the ribs can be integrally molded in. It is also contemplated that the ribs82a(FIG. 3) can be a component that is separate from the front cover58and the frame54and is dimensioned to be received into the recess84in the front cover58. The ribs82acan be secured into the opening using any one of a variety of methods, including by not limited to, fasteners, snap-fit, interference fits, adhesives, etc. The method of securing the ribs82acan be selected such that an operator can quickly and easily install and test ribs with different configurations until a rib configuration that provides a desired flow characteristic in the freezer compartment14is found. The foregoing embodiment finds particular advantageous application where the ice maker50and/or the front cover58is used in multiple refrigerators10having freezer compartments14of different sizes and configurations.

As described in several of the embodiments above, the ribs82can be formed in the frame54. It is also contemplated that the housing53of the ice bin52could include an upper front, horizontal edge portion (not shown) that is dimensioned to mate with the upper end of the back surface of the front cover58. In this embodiment, instead of the ribs82being formed in the frame54of the ice maker50, the ribs82alternatively can be formed in the housing53of the ice bin52. In this embodiment, replacement of the ribs82can be accomplished by replacing one ice bin52with another ice bin52having a desired rib configuration. Alternatively, the ribs82can be formed in the front cover58or be a separate component and the upper front, horizontal edge portion of the housing53can be positioned opposite the recess84formed in the front cover58. As such, the upper front, horizontal edge portion of the housing53would be used in a similar manner as described above for the front horizontal edge57aof the frame54.

Referring back toFIG. 4, when the ice bin52is positioned within the frame54of the ice maker50, the recess84in the front cover58is positioned adjacent the front horizontal edge57aof the frame54such that the front cover58and the front horizontal edge57aof the frame54define a gap86therebetween. The gap86defines an upper air outlet pathway “E” that fluidly communicates with the internal cavity52aof the ice bin52. The plurality of ribs82are positioned within the upper air outlet pathway “E” for redirecting the air conveyed therealong into a predetermined direction away from the ice maker50and into the freezer compartment14, as described in detail below. As discussed in detail above, it is also contemplated that the plurality of ribs82may be formed in one or both of the front cover58and the frame54, or the ribs82can be a separate component that is received into the gap86.

As noted above, it is also contemplated that the housing53of the ice bin52may include an upper front, horizontal edge portion (not shown) that mates with the upper end of the back surface of the front cover58. In this embodiment, the gap86is formed between the upper front, horizontal edge portion of the housing53and the back surface of the front cover58. As described in detail above, the ribs82can be formed in one or both of the front cover58and the housing53, or the ribs82can be a separate component that is received into the gap86.

During operation of the ice maker50, a fan (not shown) conveys air over an evaporator in the freezer compartment14. The air flowing over the evaporator is cooled to a predetermined below freezing temperature. As shown inFIG. 7, the cooled air flows into the ice maker50along the air inlet pathway “A.” A portion of the air flows along the first branch64aand a portion of the air flows along the second branch64b. The air flowing along the first branch64aflows along upper air pathway “B” and is directed over the ice tray62in the ice maker50. The low temperature of the air causes the water in the ice tray to freeze and form ice pieces. The air then exits through the channel66and is injected into the internal cavity52aof the ice bin52. A portion of the cool air in the space above the ice tray62also exits through the side opening55formed in the frame54(best seen inFIG. 2). The side opening55forms a side air outlet pathway “F” that is directed toward a central portion of the freezer compartment14to maintain the articles in the freezer compartment14in the frozen state.

Referring now toFIGS. 4 and 7, the portion of the air directed along the lower branch64ais conveyed into the internal cavity52aof the ice bin52of the ice maker50along lower air pathway “C” to maintain the ice pieces in the ice bin52in the frozen state. The air conveyed along the upper air pathway “B” combines with this lower air within the internal cavity52a. The combined air in the internal cavity52ais then forced towards a front of the ice bin52and out of the ice maker50via the gap86along the upper air outlet pathway “E.” In particular, as shown inFIG. 2, the air flowing along the upper air outlet pathway “E” is redirected by the plurality of ribs82into a direction toward a center of the freezer compartment14to cool the food therein. Preferably, the upper air outlet pathway “E” directs the cooled air in a direction similar to the cooled air exhausted along the side air outlet pathway “F.”

The air in the freezer compartment14flows in a downward direction through the freezer compartment14, is then drawn back by the evaporator fan and is recirculated along the foregoing flow pathways. As such, the air exiting the ice maker50creates an efficient circulation pattern within the freezer compartment14and eliminates cold air clustering in upper corners of the freezer compartment14for maintaining the overall contents of the freezer compartment14in the frozen state.

In addition or alternatively, the ice maker of the instant application may further be adapted to mounting and use on a freezer door. In this configuration, although still disposed within the freezer compartment, at least the ice maker (and possibly an ice bin) is mounted to the interior surface of the freezer door. It is contemplated that the ice mold and ice bin can be separated elements, in which one remains within the freezer cabinet and the other is on the freezer door.

Cold air can be ducted to the freezer door from an evaporator in the fresh food or freezer compartment, including the system evaporator. The cold air can be ducted in various configurations, such as ducts that extend on or in the freezer door, or possibly ducts that are positioned on or in the sidewalls of the freezer liner or the ceiling of the freezer liner. In one example, a cold air duct can extend across the ceiling of the freezer compartment, and can have an end adjacent to the ice maker (when the freezer door is in the closed condition) that discharges cold air over and across the ice mold. If an ice bin is also located on the interior of the freezer door, the cold air can flow downwards across the ice bin to maintain the ice pieces at a frozen state. The cold air can then be returned to the freezer compartment via the plurality of ribs discussed herein, or alternatively can be ducted back to the evaporator of the freezer compartment. A similar ducting configuration can also be used where the cold air is transferred via ducts on or in the freezer door. The ice mold can be rotated to an inverted state for ice harvesting (via gravity or a twist-tray) or may include a sweeper-finger type, and a heater can be similarly can be used. It is further contemplated that although cold air ducting from the freezer evaporator as described herein may not be used, a thermoelectric chiller or other alternative chilling device or heat exchanger using various gaseous and/or liquid fluids could be used in its place. In yet another alternative, a heat pipe or other thermal transfer body can be used that is chilled, directly or indirectly, by the ducted cold air to facilitate and/or accelerate ice formation in the ice mold. Of course, it is contemplated that the ice maker of the instant application could similarly be adapted for mounting and use on a freezer drawer.

Alternatively, it is further contemplated that the ice maker of the instant application could be used in a fresh food compartment, including the plurality of ribs used to direct air exiting an internal cavity of the removable ice bin back into the fresh food compartment, either within the interior of the cabinet or on a fresh food door. It is contemplated that the ice mold and ice bin can be separated elements, in which one remains within the fresh food cabinet and the other is on the fresh food door.

In addition or alternatively, cold air can be ducted from another evaporator in the fresh food or freezer compartment, such as the system evaporator. The cold air can be ducted in various configurations, such as ducts that extend on or in the fresh food door, or possibly ducts that are positioned on or in the sidewalls of the fresh food liner or the ceiling of the fresh food liner. In one example, a cold air duct can extend across the ceiling of the fresh food compartment, and can have an end adjacent to the ice maker (when the fresh food door is in the closed condition) that discharges cold air over and across the ice mold. If an ice bin is also located on the interior of the fresh food door, the cold air can flow downwards across the ice bin to maintain the ice pieces at a frozen state. The cold air can then be returned to the fresh food compartment via the plurality of ribs discussed herein, or alternatively can be ducted back to the compartment with the associated evaporator, such as a dedicated icemaker evaporator compartment or the freezer compartment. A similar ducting configuration can also be used where the cold air is transferred via ducts on or in the fresh food door. The ice mold can be rotated to an inverted state for ice harvesting (via gravity or a twist-tray) or may include a sweeper-finger type, and a heater can be similarly can be used. It is further contemplated that although cold air ducting from the freezer evaporator (or similarly a fresh food evaporator) as described herein may not be used, a thermoelectric chiller or other alternative chilling device or heat exchanger using various gaseous and/or liquid fluids could be used in its place. In yet another alternative, a heat pipe or other thermal transfer body can be used that is chilled, directly or indirectly, by the ducted cold air to facilitate and/or accelerate ice formation in the ice mold. Of course, it is contemplated that the ice maker of the instant application could similarly be adapted for mounting and use on a fresh food drawer.