Patent Publication Number: US-9404683-B2

Title: Refrigerator appliance

Description:
FIELD OF THE INVENTION 
     The present disclosure related generally to refrigerator appliances, and more particularly to drain assemblies in refrigerator appliances for draining liquids from ice containers. 
     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. Additionally, many refrigerator appliances include ice makers, which make ice and then retain the ice for dispensing to a user. 
     A current trend that is increasing in popularity is the desire for “nugget”, or chewable, ice. Such ice is typically stored at a relatively higher than normal temperature such as above 32 degrees Fahrenheit in some cases. However, the desire for nugget ice has disadvantages. For example, such ice stored in an ice container of an ice maker will melt. The melted water may cause the ice to stick together and lead to other undesirable results. 
     Accordingly, improved refrigerator appliances are desired in the art. In particular, refrigerator appliances which provide improved ice container drainage would be advantageous. 
     BRIEF DESCRIPTION OF THE INVENTION 
     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 and including a mullion extending between and defining the fresh food chamber and freezer chamber. The refrigerator appliance further includes a door rotatably hinged to the cabinet for accessing the fresh food chamber, the door including an inner surface and an outer surface, the door further including an ice container mounted thereon. The refrigerator appliance further includes a hinge connecting the mullion and the door, and a freezer door connected to the cabinet for accessing the freezer chamber. The refrigerator appliance further includes a drain assembly for draining a liquid from the ice container, the drain assembly providing a flow path through the hinge and the mullion to an exhaust location. 
     In accordance with another embodiment, a refrigerator appliance is disclosed. The refrigerator appliance includes a cabinet defining a fresh food chamber and a freezer chamber, and a door rotatably hinged to the cabinet for accessing the fresh food chamber, the door including an inner surface and an outer surface, the door further including an ice container mounted thereon. The refrigerator appliance further includes a drain assembly for draining a liquid from the ice container, the drain assembly providing a flow path through the door and a sidewall of the cabinet to an exhaust location. 
     In accordance with another embodiment, a refrigerator appliance is disclosed. The refrigerator appliance includes a cabinet defining a fresh food chamber and a freezer chamber, and a door rotatably hinged to the cabinet for accessing the fresh food chamber, the door including an inner surface and an outer surface, the door further including an ice container mounted thereon. The refrigerator appliance further includes a drain assembly for draining a liquid from the ice container, the drain assembly including a drain reservoir, a pump, and a drain tube, the drain reservoir in fluid communication with the ice container, the pump in fluid communication with the drain reservoir, and the drain tube extending from the pump. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: 
         FIG. 1  provides a front view of a refrigerator appliance according to an exemplary embodiment of the present subject matter; 
         FIG. 2  provides a front view of the refrigerator appliance of  FIG. 1  with refrigerator doors of the refrigerator appliance shown in an open configuration to reveal a fresh food chamber and freezer chamber of the refrigerator appliance; 
         FIG. 3  provides a side view of a portion of the interior of a door of a refrigerator appliance according to an exemplary embodiment of the present subject matter; 
         FIG. 4  provides a front view of a portion of the interior of a door of a refrigerator appliance according to an exemplary embodiment of the present subject matter; 
         FIG. 5  provides a front view of a portion of a refrigerator appliance, including a hinge between a refrigerator door and freezer door, according to an exemplary embodiment of the present subject matter; 
         FIG. 6  provides a cross-sectional view of a portion of a refrigerator appliance, including a hinge between a refrigerator door and freezer door, according to an exemplary embodiment of the present subject matter; 
         FIG. 7  provides another cross-sectional view of the portion of a refrigerator appliance illustrated in  FIG. 6 ; 
         FIG. 8  provides a side view of a portion of a refrigerator appliance according to an exemplary embodiment of the present subject matter; 
         FIG. 9  provides a side view of a portion of a refrigerator appliance, according to an exemplary embodiment of the present subject matter; 
         FIG. 10  provides a cross-sectional view of the refrigerator appliance of  FIG. 9  with a refrigerator door in a closed position; 
         FIG. 11  provides a cross-sectional view of the refrigerator appliance of  FIG. 9  with a refrigerator door in an open position; 
         FIG. 12  provides a front view of a door of a refrigerator appliance according to an exemplary embodiment of the present subject matter; and 
         FIG. 13  provides a front view of a door of a refrigerator appliance according to an exemplary embodiment of the present subject matter. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
       FIG. 1  is a front view of an exemplary embodiment of a refrigerator appliance  100 . Refrigerator appliance  100  extends between a top  101  and a bottom  102  along a vertical direction V. Refrigerator appliance  100  also extends between a first side  105  and a second side  106  along a horizontal direction H. Further, refrigerator appliance  100  extends between a front  108  and a back  109  along a transverse direction T, which may be defined perpendicular to the vertical and horizontal directions T, H. 
     Refrigerator appliance  100  includes a cabinet or housing  120  defining an upper fresh food chamber  122  and a lower freezer chamber  124  arranged below the fresh food chamber  122  on the vertical direction V. As such, refrigerator appliance  100  is generally referred to as a bottom mount refrigerator. In the exemplary embodiment, housing  120  also 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 a top freezer 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. 
     Cabinet  120  generally is formed from a plurality of walls, including opposing sidewalls  170 , each of which includes an inner surface  172  facing the chambers  122 ,  124  and an opposing outer surface  174  (see  FIGS. 9 through 11 ). Additionally, a mullion  180  extends between the chamber  122  and chamber  124 . In the embodiment illustrated, the mullion  180  extends generally along the horizontal direction H. 
     Refrigerator doors  126  are rotatably hinged to an edge of housing  120  for accessing fresh food chamber  122 . For example, an upper hinge  190  and a lower hinge  192  may couple each door  126  to the housing  120 . It should be noted that while two doors  126  in 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 door  130  is arranged below refrigerator doors  126 ,  128  for accessing freezer chamber  124 . In the exemplary embodiment, freezer door  130  is coupled to a freezer drawer (not shown) slidably coupled within freezer chamber  124 . 
       FIG. 2  is a perspective view of refrigerator appliance  100  having refrigerator doors  126 ,  128  in an open position to reveal the interior of the fresh food chamber  122 . Additionally, freezer door  130  is shown in an open position to reveal the interior of the freezer chamber  124 . 
     A door  126  of the refrigerator appliance  100  may include an inner surface  150  and an outer surface  152 . The inner surface  150  generally defines the interior of the fresh food chamber  122  when the door  126  is in a closed position as shown in  FIG. 1 , while the outer surface  152  is generally opposite the inner surface  150  and defines the exterior of the refrigerator appliance. 
     Refrigerator appliance  100  further includes a dispensing assembly  110  for dispensing water and/or ice. Dispensing assembly  110  includes a dispenser  114  positioned on an exterior portion of refrigerator appliance  100 . Dispenser  114  includes a discharging outlet  134  for accessing ice and water. A single paddle  132  is mounted below discharging outlet  134  for operating dispenser  114 . A user interface panel  136  is provided for controlling the mode of operation. For example, user interface panel  136  includes a water dispensing button (not labeled) and an ice-dispensing button (not labeled) for selecting a desired mode of operation such as crushed or non-crushed ice. 
     Discharging outlet  134  and paddle  132  are an external part of dispenser  114 , and are mounted in a recessed portion  138  defined in an outside surface of refrigerator door  126 . Recessed portion  138  is positioned at a predetermined elevation convenient for a user to access ice or water enabling the user to access ice without the need to bend-over and without the need to access freezer chamber  124 . In the exemplary embodiment, recessed portion  138  is positioned at a level that approximates the chest level of a user. 
     Further components of dispensing assembly  110  are illustrated in  FIG. 2 . Dispensing assembly  110  includes an insulated housing  142  mounted to door  126 . Due to the insulation which encloses insulated housing  142 , the temperature within insulated housing  142  can be maintained at levels different from the ambient temperature in the surrounding fresh food chamber  122 . 
     The insulated housing  142  is constructed and arranged to operate at a temperature that facilitates producing and storing ice. More particularly, the insulated housing  142  contains an ice maker for creating ice and feeding the same to an ice container  160 , both of which may be mounted on refrigerator door  126 . As illustrated in  FIG. 2 , container  160  is placed at a vertical position on refrigerator door  126  that will allow for the receipt of ice from a discharge opening  162  located along a bottom edge  164  of insulated housing  142 . 
     Referring now to  FIGS. 3 through 13 , various embodiments of a drain assembly  200  for a refrigerator appliance  100  are provided. Such drain assemblies  200  advantageously drain liquids, such as water, from the ice container  160 . 
     Referring to  FIGS. 3 through 8 , some embodiments of a drain assembly  200  are illustrated. In these embodiments, drain assembly  200  provides a flow path through a hinge, such as lower hinge  192  and the mullion  180  to an exhaust location. Such drain assemblies  200  in these embodiments may be passive “gravity-assist” assemblies, which do not require the use of a pump or other active apparatus to drain such liquids. In exemplary embodiments, the exhaust location may be an evaporator pan  202  disposed adjacent to the back  109  of the refrigerator appliance  100 , such as near the bottom  102  of the appliance  100  and extending generally along the horizontal direction H. 
     Referring to  FIGS. 3 and 4 , the drain assembly  200  in these embodiments may for example include a first conduit  210  extending from the ice compartment  160 . The conduit  210  may be in fluid communication with the ice compartment  160 , such as through a passage defined in the ice compartment  160  that a portion of the conduit  210  surrounds. The conduit  210  as shown may be disposed within the door  126 , such as between the inner surface  150  and outer surface  152  thereof. 
     As further illustrated, an electrical box  212  may be provided for the refrigerator appliance  100 , and may be disposed within the door  126 . Conduit  210  may extend between the compartment  160  and the electrical box  212 , and for example partially extend into the electrical box  212 . Further, a second conduit  214  may extend between the electrical box  212  and the hinge  192  (see  FIGS. 5 and 6 ). The conduit  214  as shown may also be disposed within the door  126 . Alternatively, however, a single conduit may extend between the ice compartment  160  and hinge  192 , or through another suitable route to the hinge  192 . 
     Tubing may facilitate liquid flow from the ice compartment  160  to the hinge  192 . Thus, in exemplary embodiment, such tubing may extend through the various conduits  210 ,  214 , which may direct the tubing and thus the liquid flow path. Alternatively, tubing may extend between the ice compartment  160  and hinge  192  without the need for outer conduits. 
     As illustrated, a first tube  216  may extend through the first conduit  210 . The first tube  216  may be in fluid communication with the ice compartment  160 , such as through the passage defined in the ice compartment  160 . Liquid may thus flow through the tube  216  (and thus through first conduit  210 ). First tube  216  may extend into the electrical box  212  as illustrated, wherein the first tube  216  may be coupled to a second tube  218 . Any suitable connection between the tubes  216 ,  218 , such as a John Guest connector  220 , is within the scope and spirit of the present disclosure. The second tube  218  may extend through the second conduit  214  and between the electrical box  212  and hinge  192 . Liquid may thus flow through the tube  218  (and thus through the second conduit  214 ). Alternatively, a single tube may extend through the conduits  210 ,  214 , or any suitable number of tubes may be utilized. 
     Referring now to  FIGS. 5 and 6 , door  126  may include a bottom cap  230  which interacts with hinge  192 . For example, bottom cap  230  may generally extend along the horizontal direction H (when the door  126  is closed), and may include a passage  232  extending generally in the vertical direction V which may cover a portion of the hinge  192 , such as a passage  194  therein that also extends generally in the vertical direction V. A closure mechanism  234  may be disposed between the passage  232  and the passage  194 , and may additionally define a passage  236  therein which extends generally in the vertical direction V. 
     Conduit  214  extending between the electrical box  212  and hinge  192  may contact bottom cap  230 , and may for example, enclose a portion of the passage  232 . Tubing which provides liquid from the ice compartment  160  may extend through the passages  232 ,  194 ,  236 , as illustrated. In exemplary embodiments, the tubing may be second tube  218 . A fitting  240  may disposed in the passages  232 ,  194 ,  236 , through which tube  218  may additionally extend, may facilitate the connection of the tube  218  within the passages and prevent the tube  218  from being inadvertently removed. For example, fitting  240  may be overmolded to an end of the tube  218 . Thus, liquid may be flowed through tubing to and through the hinge  192 . 
     Referring still to  FIGS. 5 and 6  as well as  FIG. 7 , drain assembly  200  may further include a flow connector  250 . The flow connector  250  generally facilitates the flow of liquid from the hinge  192  through the mullion  180 . For example, liquid flow through the flow connector  250  may generally be turned from flow generally in the vertical direction from hinge  192  to flow generally in the horizontal direction H to flow in the generally transverse direction T through the mullion  180 . 
     As shown, flow connector  250  may thus define a first passage  252  that extends generally along the vertical direction. The passage  252  may extend through the hinge passage  194 , and the tube  218  and fitting  240  may extend through the passage  252 . Thus, liquid may flow from the tube  218  into the passage  252  and flow connector  250  generally. 
     Flow connector  250  may further include an annulus  254  extending generally along the horizontal direction H. The annulus  254  may be in fluid communication with the passage  252 , such that liquid flowed through the passage  252  may enter the annulus  254  and flow through the annulus  254  generally in the horizontal direction H. Flow connector  250  may further include a second passage  256  extending generally along the transverse direction  256 . The second passage  256  may be in fluid communication with the annulus  254 , such that liquid flowed through the annulus  254  may enter the second passage  256  and flow through the second passage  256  generally in the transverse direction T. Accordingly, liquid may flow from the hinge  192  flow connector  250  and through the mullion  180 . 
     Flow connector  250  may generally be disposed between the door  126  and the freezer door  130 . Freezer door  130  may include a top cap  260 , which may extend generally along the horizontal direction H (when door  130  is closed). In exemplary embodiments as illustrated in  FIG. 7 , a recess  262  may be defined in the top cap  260 . Flow connector  250  may be disposed in the recess  262 , and thus be situated between doors  126 ,  130 . 
     Referring now to  FIG. 7 , the second passage  256  of flow connector  250  may extend through a bore hole defined in the mullion  180 . For example, mullion  180  may include a front mullion panel  182  and a rear structural mullion panel  184 , which may be spaced apart generally in the transverse direction T. A bore hole  186  may be defined in the front mullion panel  182 , and a bore hole  188  may be defined in the rear structural mullion panel  184 . Second passage  256  may extend through bore hole  186 , as shown. 
     Drain assembly  200  may, as illustrated, further include a fitting  270  coupled to the flow connector  250  for flowing liquid from the flow connector  250 . The fitting  270  may include a first passage  272  disposed between the rear structural mullion panel  184  and the front mullion panel  182 . The fitting  270  may further include a second passage  274  in fluid communication with the first passage  272 , which may for example extend opposite the first passage  272  such as generally along the transverse direction. The first passage  272  may further be in fluid communication with the second passage  256  of the flow connector  250 , such as by enclosing a portion of the second passage  256 , such that liquid may flow from the second passage  256  into the first passage  272 . Such liquid may then flow from the first passage  272  through the second passage  274  of the fitting  270 . 
     In exemplary embodiments as shown, a first flange  276  may extend from the first passage  272 , and a second flange  278  may extend from the second passage  274 . The first flange  276  may contact the front mullion panel  182 , thus preventing the first passage  272  from extending through the bore hole  186 . The second flange  278  may contact the rear structural mullion panel  184 , thus preventing the second passage  276  from extending through the bore hole  188 . 
     A tube  280  may extend from the fitting  270 , and thus be in fluid communication with the fitting  270  for flowing the liquid therefrom. Second passage  274  may thus be connected to the tube  280 , which may extend therefrom. Tube  280  may be inserted in (as shown) or enclose the second passage  274 , such that liquid flowed to second passage  274  flows into and through tube  280 . 
     Referring now to  FIG. 8 , liquid flow through the mullion  180  via the flow connector  250  and fitting  270  to tube  280  may then be flowed in tube  280  to an exhaust location. As illustrated, tube  280  may be directed along the outside of freezer compartment  124  (between the compartment  124  and the housing  120 ) generally to the back  109  and bottom  102  of the appliance  100 . Tube  280  may, for example, extend towards evaporator pan  202 , and may flow the liquid to the evaporator pan  202 . 
     Thus, such embodiments, facilitate the drainage of liquid along a flow path through the hinge  192  and mullion  180  to a suitable exhaust location. 
       FIGS. 9 through 11  illustrate other embodiments of the present disclosure. In these embodiments, a drain assembly  300  provides a flow path through a door  126  and a sidewall  170  to an exhaust location, such as to evaporator pan  202  as discussed above. Such drain assemblies  300  in these embodiments may also be passive “gravity-assist” assemblies, which do not require the use of a pump or other active apparatus to drain such liquids. 
     In these embodiments, a tube  302  may extend from ice compartment  160  within the door  126 , and then through the door  126  into sidewall  170 . In some embodiments, a conduit  304  may be disposed within the door  126  and in fluid communication with the ice compartment  160 , and tube  302  may extend through the conduit  304 . 
     As illustrated, door  126  may include an inner door portion  310  and an outer door portion  312 . Inner door portion  310  may include the inner surface  150  of the door  126 , while outer door portion  312  may include the outer surface  152  of the door  126 . The inner door portion  310  may generally be smaller (such as at least along the vertical direction V and the horizontal direction H when the door is closed) than the inner door portion  312 . This allows sealing between the outer door portion  312  and the chamber  122 , thus extending the inner door portion  312  into the chamber  122  when the door  126  is closed. In exemplary embodiments, the flow path for liquid from the ice compartment  160  may be provided through the inner door portion  312 , such as through the side thereof. Thus, the tube  302  and optional conduit  304  may extend through the inner door portion  312 . 
     In some embodiments as illustrated, a gasket  316  may be disposed between the door  126 , such as the inner door portion  312 , and the sidewall  170 , such as the inner surface  172  thereof, into which the tube  302  extends. Tube  302  may extend through the gasket  316 . Gasket  316  may generally protect the tube  302  and cover the tube  302  from view by a user of the refrigerator appliance  100 . 
     A conduit  318  may be disposed in the sidewall  170 , such as between the inner surface  172  and the outer surface  174 . Tube  302  may extend into the sidewall  302  and through conduit  318 , and may terminate in the conduit  318 . Thus, liquid flowed from the ice compartment  160  through the tube  302  may flow from the tube  302  through the conduit  318 . 
     A second tube  320  may extend from the conduit  318 , and liquid flowed from the first tube  302  may flow into this second tube  320 . The second tube  320  may extend within and through the sidewall  170 , and may extend to an exhaust location, such as to the evaporator pan  202  as discussed above. For example, tube  320  may exit the sidewall  170  through the inner surface  172  or outer surface  174  thereof, and extend by or between chamber  124  and housing  120  to an exhaust location. 
       FIG. 10  illustrates the drain assembly  300  according to these embodiments with the door  126  in a closed position, while  FIG. 11  illustrates the drain assembly  300  according to these embodiments with the door  126  in an open position. As illustrate, a portion of the tube  302  moves relative to conduit  318  when the door  126  is in the open position. Thus, tube  302  generally may have a length such that it extends through the conduit  218  when the door  126  is in the open position. 
     Thus, such embodiments facilitate the drainage of liquid along a flow path through the door  126  and sidewall  170  to a suitable exhaust location. 
       FIGS. 12 and 13  illustrate other embodiments of the present disclosure. In these embodiments, a drain assembly  400  provides other suitable flow paths for liquid from the ice compartment  160 . Such drain assemblies  200  in these embodiments may be active assemblies, which utilized pumps or other suitable devices to facilitate draining. 
     For example, as illustrated, drain assembly  400  may include a drain reservoir  402  mounted to or disposed within the door  126 . The drain reservoir  402  may be in fluid communication, through for example a tube or conduit  404 , with the ice compartment  160 . Liquid may thus flow from the ice compartment  160  to the reservoir  402 . Further, a pump  406  may be in fluid communication with the drain reservoir  402 , for pumping liquid from the drain reservoir  402 . Pump  406  additionally may be mounted to or disposed within the door  126 . A tube or conduit  408  may provide such fluid communication. 
     A liquid level sensor  410  may be provided in the drain reservoir  402 , as illustrated. Sensor  410  may sense the liquid level in the reservoir  402 . Sensor  410  may be in communication with the pump  406 , such as through a suitable wired or wireless connection, and may activate the pump  406  when a predetermined liquid level is met or exceeded in the reservoir  402 . Thus, liquid flowed into the reservoir  402  may be flowed out of the reservoir  402  by and through the pump  406 . 
     A drain tube  412  may extend from the pump  406 , and may flow the liquid from the pump  406 . Further, optional conduits (not shown) may house the tube  412  therein and direct the tube  412  from the pump  406 . Tube  412  and optional conduits may be mounted to or disposed within the door  126 . 
     In some embodiments, the drain tube  412  may be routed out of the door  126  to a suitable exhaust location, such as to evaporator pan  202 . For example, as illustrated in  FIG. 10 , drain tube  412  may extend through hinge  190 , such as through a passage  196  extending through the hinge  190  generally in the vertical direction V. The tube  412  may then extend towards a suitable exhaust location. 
     In other embodiments, the drain tube  412  may be routed to recycle the liquid. Thus, for example, the drain tube  412  may extend to and be in fluid communication with a liquid reservoir  414  which may be mounted to or disposed within the door  126  and in fluid communication with the insulated housing  142  in which the ice maker is disposed. The drain tube  412  may thus exhaust the liquid into the liquid reservoir  414 , where it may further be flowed into the housing  142  and made into ice. In these embodiments, a filter  416  may additionally be provided along the flow path, such as between and in fluid communication with the pump  406  and drain tube  412 . The liquid may flow through the filter  416  and thus be filtered before reuse in the insulated housing  142 . 
     Thus, such embodiments facilitate various active embodiments for the drainage of liquid along various flow paths. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.