U.S. patent application number 14/829967 was filed with the patent office on 2017-02-23 for injection-molded refrigerator liner with air ducts.
The applicant listed for this patent is General Electric Company. Invention is credited to Wade Antoine Powell.
Application Number | 20170051966 14/829967 |
Document ID | / |
Family ID | 58158224 |
Filed Date | 2017-02-23 |
United States Patent
Application |
20170051966 |
Kind Code |
A1 |
Powell; Wade Antoine |
February 23, 2017 |
INJECTION-MOLDED REFRIGERATOR LINER WITH AIR DUCTS
Abstract
An injection-molded door liner for a door of a refrigerator
appliance is provided. The door liner is injection molded as a
single, integral piece and defines an icebox compartment, a cooling
air inlet duct, and a cooling air outlet duct. A sealed cooling
system circulates cooling air into the icebox compartment through
the cooling air inlet duct and the cooling air is returned to the
sealed cooling system through the cooling air outlet duct.
Inventors: |
Powell; Wade Antoine; (La
Grange, KY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Family ID: |
58158224 |
Appl. No.: |
14/829967 |
Filed: |
August 19, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25D 23/068 20130101;
F25D 2317/067 20130101; F25C 5/185 20130101; F25D 23/04 20130101;
F25D 23/087 20130101; F25D 23/064 20130101; F25C 2400/10 20130101;
F25D 2317/062 20130101; F25D 17/065 20130101 |
International
Class: |
F25D 23/04 20060101
F25D023/04; F25D 23/02 20060101 F25D023/02; F25D 23/08 20060101
F25D023/08; F25C 5/18 20060101 F25C005/18; F25D 17/04 20060101
F25D017/04 |
Claims
1. An injection molded door liner for a door of a refrigerator
appliance, the door liner comprising: an icebox compartment defined
at least in part by the door liner, the icebox compartment having a
back wall and a plurality of sidewalls; a cooling air inlet duct
defined by the door liner and configured to receive cooling air
from a sealed cooling system; and a cooling air outlet duct defined
by the door liner and configured to return cooling air to the
sealed cooling system, wherein the door liner is injection molded
as a single, integral part.
2. The injection molded door liner of claim 1, wherein the door
liner defines a space around each of the inlet duct and the outlet
duct, such that the inlet duct and the outlet duct may be
surrounded in insulating foam.
3. The injection molded door liner of claim 1, wherein the cooling
air inlet duct and the cooling air outlet duct extend from a first
end proximate to one of the plurality of sidewalls of the icebox
compartment to a second end proximate to a door mating surface
defined by the door liner.
4. The injection molded door liner of claim 3, wherein the second
end of the inlet duct is configured to receive an inlet duct gasket
and the second end of the outlet duct is configured to receive an
outlet duct gasket.
5. The injection molded door liner of claim 4, wherein the inlet
duct gasket is compressed to form a seal with a cooling air supply
duct and the outlet duct gasket is compressed to form a seal with a
cooling air return duct when the door is in a closed position.
6. The injection molded door liner of claim 1, wherein the door
liner is between about 1/16 inch and 3/16 inch thick.
7. The injection molded door liner of claim 1, wherein the door
liner is about 1/8 inch thick.
8. The injection molded door liner of claim 1, wherein the inlet
duct and the outlet duct each comprise a rectangular profile having
radiused corners.
9. The injection molded door liner of claim 1, wherein the inlet
duct and the outlet duct each comprise an oblong profile.
10. The injection molded door liner of claim 1, wherein the door
liner is disposed in a fresh food chamber and the icebox
compartment comprises an ice maker and an ice storage bin.
11. A refrigerator appliance, comprising: a cabinet including a
liner defining a chilled chamber; a door configured to provide
access into the chilled chamber; a door liner that is injection
molded as a single, integral piece and mounted in the door, the
door liner defining a sub-compartment, the sub-compartment
comprising: an icebox cavity; an inlet for receiving chilled air
into the icebox cavity from a sealed cooling system; and an outlet
for returning chilled air to the sealed cooling system.
12. The refrigerator appliance of claim 11, wherein the door liner
defines a space around each of the inlet and the outlet, such that
the inlet and the outlet may be surrounded in insulating foam.
13. The refrigerator appliance of claim 11, wherein the inlet and
the outlet extend from a first end proximate to the icebox cavity
to a second end proximate to a door mating surface defined by the
door liner.
14. The refrigerator appliance of claim 13, wherein the second end
of the inlet is configured to receive an inlet gasket and the
second end of the outlet is configured to receive an outlet
gasket.
15. The refrigerator appliance of claim 14, wherein the inlet
gasket is compressed to form a seal with a chilled air supply duct
and the outlet gasket is compressed to form a seal with a chilled
air return duct when the door is in a closed position.
16. The refrigerator appliance of claim 11, wherein the door liner
is between about 1/16 inch and 3/16 inch thick.
17. The refrigerator appliance of claim 11, wherein the door liner
is about 1/8 inch thick.
18. The refrigerator appliance of claim 11, wherein the inlet and
the outlet each comprise a rectangular profile having radiused
corners.
19. The refrigerator appliance of claim 11, wherein the inlet and
the outlet each comprise an oblong profile.
20. The refrigerator appliance of claim 11, wherein the icebox
cavity comprises an ice maker and an ice storage bin.
Description
FIELD OF THE INVENTION
[0001] The present subject matter relates generally to appliances,
such as refrigerator appliances, and liners for the same.
BACKGROUND OF THE INVENTION
[0002] Certain refrigerator appliances utilize sealed systems for
cooling chilled chambers of the refrigerator appliances. A typical
sealed system includes an evaporator and a fan, the fan generating
a flow of air across the evaporator and cooling the flow of air.
The cooled air is then provided through an opening into the chilled
chamber to maintain the chilled chamber at a desired temperature.
Air from the chilled chamber is circulated back through a return
duct to be re-cooled by the sealed system during operation of the
refrigerator appliance, maintaining the chilled chamber at the
desired temperature.
[0003] In some refrigerator appliances, an ice maker may be mounted
in a fresh food chamber. The ice maker may have a mold body
configured to receive water that can freeze over time to form ice
cubes. However, because the fresh food chamber is generally
maintained at a temperature above the freezing point of water, the
ice maker must be contained within a chilled chamber that is
maintained at a freezer temperature. In order to achieve this, the
ice maker is typically placed in a chilled chamber having an inlet
and an outlet. A sealed system has a fan that circulates chilled
air through the chamber by delivering the chilled air to the
chilled chamber through the inlet and receiving the return air from
the outlet.
[0004] A chilled chamber for housing an icemaker may be disposed in
the refrigerator door of a bottom mount refrigerator. Such
refrigerator doors commonly include an outer door frame, a door
liner, and foam insulation. The outer door frame is typically
constructed of rigid material such as steel and is stamped or
otherwise formed to the desired door shape. The door liner is
typically formed from a combination of injection-molded and
thermoformed parts. The door liner is then sealed against the outer
door frame to form an insulating cavity. Insulating foam is then
sprayed inside the cavity to provide insulation and structural
support for the door liner.
[0005] The inlet and outlet of the chilled chamber are typically
formed by injection-molding or thermoforming a skeleton of the door
liner and piercing holes for the inlet and outlet. To complete the
formation of the inlet and outlet ducts, a separate thermoformed
duct is formed and joined with the door liner. The additional parts
require separate design, tooling, procurement, and storage. The
joints are typically welded together or joined using tapes and
adhesive. However, the holes and joints in the door liner create
leak points that cause issues during the foam insulation process.
Moreover, the holes may not have sufficient structural integrity,
and may separate during the foam insulation process. Indeed, foam
leaks around the air ducts of these assemblies are not uncommon,
and frequently result in the scrapping of expensive foam door
assemblies.
[0006] Accordingly, a refrigerator appliance including an
injection-molded door liner that is integrally formed would be
useful. More particularly, a door liner for a refrigerator
appliance including an icebox defining an inlet and an outlet
without requiring assembly of multiple parts would be especially
beneficial.
BRIEF DESCRIPTION OF THE INVENTION
[0007] The present subject matter provides an injection-molded door
liner for a refrigerator door and a method for forming such a door
liner. More particularly, the door liner is injection molded as a
single, integral piece and defines an icebox compartment, a cooling
air inlet duct, and a cooling air outlet duct. A sealed cooling
system circulates cooling air into the icebox compartment through
the cooling air inlet duct and the cooling air is returned to the
sealed cooling system through the cooling air outlet duct. The door
liner simplifies assembly, reduces parts, and minimizes the
likelihood of leaks. The door liner thereby reduces costs while
increasing refrigerator performance and efficiency. 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.
[0008] In a first exemplary embodiment, an injection molded door
liner for a door of a refrigerator appliance is provided. The door
liner includes an icebox compartment defined at least in part by
the door liner and having a back wall and a plurality of sidewalls.
A cooling air inlet duct is defined by the door liner and is
configured to receive cooling air from a sealed cooling system. A
cooling air outlet duct is defined by the door liner and is
configured to return cooling air to the sealed cooling system. The
door liner is injection molded as a single, integral part.
[0009] According to another exemplary embodiment, a refrigerator
appliance is provided. The refrigerator appliance includes a
cabinet including a liner defining a chilled chamber and a door
configured to provide access into the chilled chamber. A door liner
is injection molded as a single, integral piece and is mounted in
the door. The door liner defines a sub-compartment including an
icebox cavity, an inlet for receiving chilled air into the icebox
cavity from a sealed cooling system, and an outlet for returning
chilled air to the sealed cooling system.
[0010] 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
[0011] 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.
[0012] FIG. 1 provides a perspective view of a refrigerator
appliance according to an exemplary embodiment of the present
subject matter.
[0013] FIG. 2 provides a perspective view of the exemplary
refrigerator appliance of FIG. 1 with refrigerator doors of the
refrigerator appliance shown in an open position to reveal a fresh
food chamber of the refrigerator appliance.
[0014] FIG. 3 provides an exploded perspective view of the
refrigerator appliance door of FIG. 1 showing a door liner defining
an icebox compartment.
[0015] FIG. 4 provides a schematic view of a sealed cooling system
of the refrigerator appliance of FIG. 1.
[0016] FIG. 5 provides a perspective view of a door liner of the
exemplary refrigerator appliance of FIG. 1.
[0017] FIG. 6 provides a rear view of the door liner of the
exemplary refrigerator appliance of FIG. 1.
[0018] FIG. 7 provides a cross-sectional view of the cooling air
inlet and outlet ducts defined in the door liner of the exemplary
refrigerator appliance of FIG. 1 taken along Line 7-7 in FIG.
6.
[0019] FIG. 8 provides a close-up, perspective view of a cooling
air inlet duct of the door liner of the exemplary refrigerator
appliance of FIG. 1.
[0020] FIG. 9 provides a perspective view of a door liner of the
exemplary refrigerator appliance of FIG. 1.
[0021] FIG. 10A provides a plot of a measured pressure drop of
cooling air as it is circulated through the icebox compartment of
the refrigerator appliance of FIG. 1 compared to the pressure drop
in a prior design over various cooling air flow rates.
[0022] FIG. 10B provides a plot of a measured pressure drop of
cooling air flowing across the inlet duct and the outlet duct of
the icebox compartment of the refrigerator appliance of FIG. 1
compared to the pressure drop in a prior design over various
cooling air flow rates.
DETAILED DESCRIPTION
[0023] 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.
[0024] FIG. 1 provides a perspective view of a refrigerator
appliance 100 according to an exemplary embodiment of the present
subject matter. Refrigerator appliance 100 includes a cabinet or
housing 120 that extends between a top 101 and a bottom 102 along a
vertical direction V. Housing also extends along a lateral
direction L and a transverse direction T, each of the vertical
direction V, lateral direction L, and transverse direction T being
mutually perpendicular to one another. Housing 120 defines chilled
chambers for receipt of food items for storage. In particular,
housing 120 defines fresh food chamber 122 positioned at or
adjacent top 101 of housing 120 and a freezer chamber 124 arranged
at or adjacent bottom 102 of housing 120. As such, refrigerator
appliance 100 is generally referred to as a bottom mount
refrigerator. It is recognized, however, that the benefits of the
present disclosure apply to other types and styles of refrigerator
appliances such as, e.g., a top mount refrigerator appliance or a
side-by-side style refrigerator appliance. Consequently, the
description set forth herein is for illustrative purposes only and
is not intended to be limiting in any aspect to any particular
refrigerator chamber configuration.
[0025] Refrigerator doors 128 are rotatably hinged to an edge of
housing 120 for selectively accessing fresh food chamber 122. In
addition, a freezer door 130 is arranged below refrigerator doors
128 for selectively accessing freezer chamber 124. Freezer door 130
is coupled to a freezer drawer (not shown) slidably mounted within
freezer chamber 124. Refrigerator doors 128 and freezer door 130
are shown in the closed configuration in FIG. 1.
[0026] Refrigerator appliance 100 also includes a dispensing
assembly 140 for dispensing liquid water and/or ice. Dispensing
assembly 140 includes a dispenser 142 positioned on or mounted to
an exterior portion of refrigerator appliance 100, e.g., on one of
refrigerator doors 128. Dispenser 142 includes a discharging outlet
144 for accessing ice and liquid water. An actuating mechanism 146,
shown as a paddle, is mounted below discharging outlet 144 for
operating dispenser 142. In alternative exemplary embodiments, any
suitable actuating mechanism may be used to operate dispenser 142.
For example, dispenser 142 can include a sensor (such as an
ultrasonic sensor) or a button rather than the paddle. A control
panel 148 is provided for controlling the mode of operation. For
example, control panel 148 includes a plurality of user inputs (not
labeled), such as a water dispensing button and an ice-dispensing
button, for selecting a desired mode of operation such as crushed
or non-crushed ice.
[0027] Discharging outlet 144 and actuating mechanism 146 are an
external part of dispenser 142 and are mounted in a dispenser
recess 150. Dispenser recess 150 is positioned at a predetermined
elevation convenient for a user to access ice or water and enabling
the user to access ice without the need to bend-over and without
the need to open refrigerator doors 128. In the exemplary
embodiment, dispenser recess 150 is positioned at a level that
approximates the chest level of a user. As described in more detail
below, the dispensing assembly 140 may receive ice from an icemaker
disposed in a sub-compartment of the fresh food chamber 122.
[0028] FIG. 2 provides a perspective view of a door of refrigerator
appliance 100 shown with refrigerator doors 128 in the open
position. Refrigerator appliance 100 includes a sub-compartment,
e.g., icebox compartment 160 defined on refrigerator door 128.
Icebox compartment 160 extends into fresh food chamber 122 when
refrigerator door 128 is in the closed position. As discussed in
greater detail below, an ice making assembly or icemaker 210 and an
ice storage bin 208 (FIG. 3) may be positioned or disposed within
icebox compartment 160. Thus, ice is supplied to dispenser recess
150 (FIG. 1) from the icemaker 210 and ice storage bin 208 in
icebox compartment 160 on a back side of refrigerator door 128.
[0029] An access door 162 is hinged to refrigerator door 128 or to
icebox compartment 160. Access door 162 permits selective access to
icebox compartment 160. Any manner of suitable latch 164 is
configured with icebox compartment 160 to maintain access door 162
in a closed position. As an example, latch 164 may be actuated by a
consumer in order to open access door 162 for providing access into
icebox compartment 160. Access door 162 can also assist with
insulating icebox compartment 160, e.g., by thermally isolating or
insulating icebox compartment 160 from fresh food chamber 122.
[0030] According to the illustrated embodiment, various storage
components are mounted within fresh food chamber 122 to facilitate
storage of food items therein as will be understood by those
skilled in the art. In particular, the storage components include
bins 166, drawers 168, and shelves 170 that are mounted within
fresh food chamber 122. Bins 166, drawers 168, and shelves 170 are
configured for receipt of food items (e.g., beverages and/or solid
food items) and may assist with organizing such food items. As an
example, drawers 168 can receive fresh food items (e.g.,
vegetables, fruits, and/or cheeses) and increase the useful life of
such fresh food items.
[0031] As will be discussed below, refrigerator appliance 100
includes an icemaker 210 for producing ice within icebox
compartment 160. In order to maintain icebox compartment 160 at a
temperature below the freezing point of water, chilled air supply
duct 180 and chilled air return duct 182 may be disposed on a side
portion of the housing 120 of the refrigerator appliance 100. In
this manner, the supply duct 180 and return duct 182 may
recirculate chilled air from a sealed cooling system 250 through
icebox compartment 160.
[0032] FIG. 3 shows an exploded perspective view of the
refrigerator door 128. As explained above, refrigerator door 128 is
an outer door movable between a closed position (FIG. 1) closing
fresh food chamber 122 and an opened position allowing access to
the interior of fresh food chamber 122 (FIG. 2). Refrigerator door
128 may have an outer panel 202 and an injection-molded door liner
204 attached to an inside of outer panel 202. Insulation (not
shown), such as expandable foam can be present between outer panel
202 and door liner 204 in order to assist with insulating fresh
food chamber 122 and icebox compartment 160. For example sprayed
polyurethane foam may be injected into a cavity defined between
outer panel 202 and door liner 204 after they are assembled.
[0033] Outer panels 202 and door liners 204 may be constructed of
or with any suitable materials. Typically, outer panel 202 includes
a main body formed of a structurally firm metal material such as
steel, stainless steel, painted steel, aluminum, or any other
suitably rigid material. Outer panel 202 may also have multiple
inner and outer layers (not shown) as is known to provide coloring,
fingerprint and smudge avoidance, insulation adhesion, etc. Freezer
door 130 may be constructed in a similar manner as refrigerator
doors 128.
[0034] Door liner 204 may be constructed of or with a suitable
plastic material. For example, door liner 204 may be
injection-molded plastic such as HIPS (high impact
polystyrene--injection molding grade) or ABS (injection molding
grade), which is typically more rigid than that of a thermoformed
liner. Door liner 204 may define icebox compartment 160, which is
formed of injection molded plastic. Accordingly, icebox compartment
160 provides a rigid frame on which various elements can be mounted
to refrigerator door 128.
[0035] Icebox compartment 160 includes an interior area 206 (FIG.
5) in which an ice storage bin 208 may be removably located. In
addition, an icemaker 210 may be disposed within the icebox
compartment 160 and may be configured for forming ice which may be
stored in ice storage bin 208. Ice storage bin 208 and icemaker 210
may be readily attached to icebox compartment 160 using, for
example, clips, fasteners, or other securing means. Icemaker 210
may include a mold body 212 for receipt of water for freezing. In
particular, mold body can receive liquid water and such liquid can
freeze therein and form ice cubes. Icemaker 210 can harvest such
ice cubes and direct such ice cubes to the ice storage bin 208
positioned within icebox compartment 160. For example, a motor 214
for driving an auger 216 for assisting in moving ice cubes from ice
storage bin 208 can also be mounted directly in icebox compartment
160. Ice cubes at the bottom of the ice storage bin 208 can enter
an ice chute (not shown) and flow through refrigerator door 128 to
discharging outlet 144 and flow into a container or cup, e.g., in
the manner discussed above. Access door 162 may enclose the
interior area 206 of icebox compartment 160 and any items
therein.
[0036] Various elements can be attached directly to icebox
compartment 160, as mentioned above. For example, at least one of
an ice storage bin 208, an icemaker 210, and a motor 214 for
driving an auger 216 can be located in and be attached to the
icebox compartment 160. In addition, other suitable electrical,
liquid, and mechanical attachments can be provided within icebox
compartment 160 in any desirable combination or configuration.
Notably, because icebox compartment 160 is made of rigid
injection-molded plastic, a more secure attachment and resulting
structure can be achieved than if the icebox compartment 160 were
simply a thermoformed liner.
[0037] As will be understood by those skilled in the art, ambient
air within fresh food chamber 122 is not maintained at a
sufficiently low temperature to permit formation of ice by icemaker
210. Thus, icebox compartment 160 is isolated or insulated from
fresh food chamber 122 and includes features for facilitating
formation of ice by icemaker 210. For example, chilled air from a
sealed cooling system 250 (described in detail below) of
refrigerator appliance 100 may be directed into icebox compartment
160 in order to cool icemaker 210 and/or ice storage bin 208. In
alternative exemplary embodiments, a temperature of air within
icebox compartment 160 may correspond to a temperature of air
within fresh food chamber 122, such that ice within ice storage bin
208 melts over time.
[0038] To facilitate formation of ice within icemaker 210, icebox
compartment 160 includes a chilled air inlet duct 220 and a chilled
air outlet duct 222. Chilled air inlet duct 220 and chilled air
outlet duct 222 are vertically aligned with chilled air supply duct
180 and chilled air return duct 182, respectively, positioned on
housing 120. Chilled air ducts 180, 182 are in fluid communication
with freezer chamber 124 and can receive chilled air therefrom and
direct chilled air into icebox compartment 160. Chilled air can
assist within formation of ice by icemaker 210 and/or storage of
ice within ice storage bin 208. As an example, chilled air inlet
duct 220 can receive chilled air from freezer chamber 124 via
chilled air supply duct 180. Because chilled air within freezer
chamber 124 can have a sufficiently low temperature to permit
formation of ice, chilled air therefrom can assist or permit
icemaker 210 to produce ice despite being positioned adjacent fresh
food chamber 122. To facilitate the flow of chilled air from
freezer chamber 124 to icemaker 210, chilled air outlet duct 222
can direct air within icebox compartment 160 away from icemaker
210, e.g., back to freezer chamber 124 via chilled air return duct
182.
[0039] Access door 162 can be used to maintain interior area 206 at
a temperature lower than that of fresh food chamber 122, for
example below freezing. Access door 162 can be hinged to door liner
104, or may simply be removable from door liner 104. By defining
chilled air inlet and outlet ducts 220, 222 to cool interior area
206, icebox 160 need not be separately cooled, although a fan or
other device may be employed to move cooled air from freezer
chamber 124 into the interior area 206. An ice dispenser outlet
(not shown) is provided to feed ice cubes from interior area 206
and ice storage bin 208 through as passageway in outer panel 202
and door liner 204 and through to dispenser 142.
[0040] As is known in the art, a heating element 228 may be
provided in icebox compartment 160 to prevent or reduce undesired
condensation in view of the fact that icebox compartment 160 may be
located within refrigerator door 128 of fresh food chamber 122,
which is at a different temperature than the sub-freezing
temperature inside icebox compartment 160. Heating element 228 also
prevents undesired freezing of any condensation that might form at
such location, which may clog the icemaker 210 or might possibly
make it more difficult to open access door 162. Heating element 228
may be a strip resistance heater located in icebox compartment 160,
and may be, for example attached to door liner 204.
[0041] As shown, icebox compartment 160 is defined by door liner
204 of refrigerator door 128. However, one skilled in the art will
appreciate that icebox compartment 160 may be located on any
surface of housing 120. For example, it could just as easily be
located on freezer door 130 of freezer chamber 124 or configured
according to other appliance/door designs. In addition, embodiments
of the present subject matter may be employed to construct door
liners for components other than icebox compartment 160. For
example, the technologies described herein may be used to construct
integral cabinets, shelving, and other features for refrigerator
appliance 100.
[0042] FIG. 4 provides a schematic view of certain components of
refrigerator appliance 100. As may be seen in FIG. 4, refrigerator
appliance 100 includes a sealed cooling system 250 for executing a
vapor compression cycle for cooling air within refrigerator
appliance 100, e.g., within fresh food chamber 122 and freezer
chamber 124. Sealed cooling system 250 includes a compressor 252, a
condenser 254, an expansion device 256, and an evaporator 258
connected in series and charged with a refrigerant. As will be
understood by those skilled in the art, sealed cooling system 250
may include additional components, e.g., at least one additional
evaporator, compressor, expansion device, and/or condenser. As an
example, sealed cooling system 250 may include two evaporators.
[0043] Within sealed cooling system 250, gaseous refrigerant flows
into compressor 252, which operates to increase the pressure of the
refrigerant. This compression of the refrigerant raises its
temperature, which is lowered by passing the gaseous refrigerant
through condenser 254. Within condenser 254, heat exchange with
ambient air takes place so as to cool the refrigerant and cause the
refrigerant to condense to a liquid state.
[0044] Expansion device (e.g., a valve, capillary tube, or other
restriction device) 256 receives liquid refrigerant from condenser
254. From expansion device 256, the liquid refrigerant enters
evaporator 258. Upon exiting expansion device 256 and entering
evaporator 258, the liquid refrigerant drops in pressure and
vaporizes. Due to the pressure drop and phase change of the
refrigerant, evaporator 258 is cool relative to fresh food and
freezer chambers 122 and 124 of refrigerator appliance 100. As
such, cooled air is produced and refrigerates fresh food and
freezer chambers 122 and 124 of refrigerator appliance 100. Thus,
evaporator 258 is a type of heat exchanger which transfers heat
from air passing over evaporator 258 to refrigerant flowing through
evaporator 258.
[0045] Refrigerator appliance 100 further includes a valve 260 for
regulating a flow of liquid water to icemaker 210, e.g., into a
mold body of icemaker 210. Valve 260 is selectively adjustable
between an open configuration and a closed configuration. In the
open configuration, valve 260 permits a flow of liquid water to
icemaker 210. Conversely, in the closed configuration, valve 260
hinders the flow of liquid water to icemaker 210.
[0046] Refrigerator appliance 100 also includes an air handler 262.
Air handler 262 is configured for urging a flow of chilled air from
freezer chamber 124 into icebox compartment 160, e.g., via supply
and return ducts 180, 182 and chilled air ducts 220, 222, as
discussed above. Air handler 262 can be positioned within supply
and return ducts 180, 182 of sealed cooling system 250 and be any
suitable device for moving air. For example, air handler 262 can be
an axial fan or a centrifugal fan.
[0047] Refrigerator appliance 100 further includes a controller
264. Operation of the refrigerator appliance 100 is regulated by
controller 264 that is operatively coupled to control panel 148. In
one exemplary embodiment, control panel 148 may represent a general
purpose I/O ("GPIO") device or functional block. In another
exemplary embodiment, control panel 148 may include input
components, such as one or more of a variety of electrical,
mechanical or electro-mechanical input devices including rotary
dials, push buttons, touch pads, and touch screens. Control panel
148 may be in communication with controller 264 via one or more
signal lines or shared communication busses. Control panel 148
provides selections for user manipulation of the operation of
refrigerator appliance 100. In response to user manipulation of the
control panel 148, controller 264 operates various components of
refrigerator appliance 100. For example, controller 264 is
operatively coupled or in communication with compressor 252, valve
260, and air handler 262, such that controller 264 can operate such
components. Controller 264 may also be in communication with a
variety of sensors, such as, for example, a temperature sensor 266.
Controller 264 may receive signals from temperature sensor 266 that
correspond to a temperature of an atmosphere or air within, e.g.,
icebox compartment 160.
[0048] Controller 264 includes memory and one or more processing
devices such as microprocessors, CPUs or the like, such as general
or special purpose microprocessors operable to execute programming
instructions or micro-control code associated with operation of
refrigerator appliance 100. The memory can represent random access
memory such as DRAM, or read only memory such as ROM or FLASH. The
processor executes programming instructions stored in the memory.
The memory can be a separate component from the processor or can be
included onboard within the processor. Alternatively, controller
264 may be constructed without using a microprocessor, e.g., using
a combination of discrete analog and/or digital logic circuitry
(such as switches, amplifiers, integrators, comparators,
flip-flops, AND gates, and the like) to perform control
functionality instead of relying upon software.
[0049] Referring now to FIG. 5, a perspective view of door liner
204 of exemplary refrigerator appliance 100. According to the
illustrated exemplary embodiment, door liner 204 is injection
molded as a single, integral part and configured to be mounted on
refrigerator door 128 of refrigerator appliance 100. Door liner 204
may define a lower compartment 280 which may receive, for example,
a variety of mechanical components used for operating the
dispensing assembly 140. For example, lower compartment 280 of door
liner 204 may receive a water tank, one or more valves, or other
mechanical components. In such an embodiment, a separate cover (not
shown) is typically placed over lower compartment 280 to conceal
the mechanical components. Additionally, or alternatively, lower
compartment 280 may receive a door storage bin (not shown) or may
be used in any other suitable manner.
[0050] The door liner 204 may also define an upper compartment,
e.g., icebox compartment 160. As shown in the illustrated
embodiment, icebox compartment 160 is defined by a plurality of
walls. More particularly, icebox compartment 160 generally includes
a rear wall 282, a first sidewall 284, a laterally opposite second
sidewall 286, a top wall 288, and a bottom wall 290. As described
above, access door 162 (FIG. 2) can be used to provide selective
access to icebox compartment 160.
[0051] As explained above, refrigerator appliance 100 includes a
sealed cooling system 250 for delivering chilled air to icebox
compartment 160 defined by door liner 204. More particularly,
icebox compartment 160 defines an inlet--e.g., cooling air inlet
duct 220--which is defined by door liner 204 and may be configured
to receive cooling air from the sealed cooling system 250 via
supply duct 180. Similarly, icebox compartment 160 defines an
outlet--e.g., cooling air outlet duct 222--which is defined by door
liner 204 and may be configured to return cooling air from the
sealed cooling system 250 via return duct 182. For the embodiment
depicted, cooling air inlet duct 220 is defined in first sidewall
284 of door liner 204 proximate to the top wall 288 and cooling air
outlet duct 222 is defined in first sidewall 284 of liner 204
proximate to the bottom wall 290.
[0052] As described above, refrigerator appliance 100 includes air
handler 262 to provide a flow of cooling air from sealed cooling
system 250 to icebox compartment 160. More specifically, chilled
air travels from supply duct 180 in cabinet 120, through cooling
air inlet duct 220, and into icebox compartment 160. The chilled
air lowers the temperature in icebox compartment 160 before passing
through return duct 182 and back to the sealed cooling system 250
through chilled air outlet duct 222. In this manner, the sealed
cooling system 250 distributes chilled air throughout the icebox
compartment 160 to maintain the temperature at freezer temperature
so that ice may be formed.
[0053] Referring now to FIGS. 6 and 7, inlet duct 220 and outlet
duct 222 will be described in more detail. Although the inlet duct
220 is used here for the purposes of description, the outlet duct
222 may be similarly formed according to an exemplary embodiment.
The inlet duct 220 may extend from a first end 292 proximate to one
of the plurality of sidewalls of the icebox compartment--e.g.,
first sidewall 284--to a second end 294 proximate to a door mating
surface 296 defined by door liner 204. As shown in the illustrated
embodiment, the inlet duct 220 extends in a substantially
orthogonal direction from first sidewall 284. However, inlet duct
220 may alternatively extend from first sidewall 284 in a different
direction and/or from a different wall of icebox compartment 160.
Notably, as shown in the illustrated embodiment of FIGS. 6 and 7,
door liner 204 defines a space 298 around each of the inlet duct
220 and the outlet duct 222, such that the inlet duct 220 and the
outlet duct 222 may be surrounded in insulating foam (not
shown).
[0054] Referring now to FIGS. 8 and 9, it can be seen that the
second end 294 of inlet duct 220 is disposed at the door mating
surface 296. As shown, the injection molded door liner 204 may
define inlet duct 220 and outlet duct 222 such that they each
comprise a rectangular profile having radiused corners.
Alternatively, inlet duct 220 and outlet duct 222 may each comprise
an oblong profile, or any other suitable profile for enhancing
cooling airflow and system performance. In addition, by virtue of
the injection molding process, the transitions, corners, or edges
defining the profile of inlet duct 220 and outlet duct 222 may be
molded to have a smooth profile, to have small or large radiused
corners, or to have another flow enhancing profile, as desired.
[0055] For example, the second end 294 of the inlet duct 220 may be
configured to receive a duct gasket 310 (FIG. 9). In this regard,
injection molded door liner 204 may define a profile that is
configured to securely accept door gasket 310. Alternatively,
according to another exemplary embodiment, door liner 204 may be
configured to receive a duct bracket (not shown) which is
configured to receive the duct gasket 310. As shown, duct gasket
310 protrudes from door mating surface 296 of door liner 204 and is
typically made from a resilient material, e.g., rubber. In this
manner, duct gasket 310 may be compressed to form a seal with
supply duct 180 when refrigerator door 128 is in the closed
position. Similarly, outlet duct 222 may be configured to receive
duct gasket 310, which is compressed to form a seal with return
duct 182 when refrigerator door 128 is in a closed position.
According to another embodiment, duct gasket 310 may be disposed on
housing 120 of refrigerator appliance 100. In this regard, duct
gasket 310 surrounds supply duct 180 and return duct 182. For this
embodiment, door mating surface 296 of door liner 204 may define a
profile for receiving the duct gasket 310 and providing a seal
between, for example, supply duct 180 and inlet duct 220.
[0056] Although the exemplary embodiments described above refer to
an integral, injection-molded door liner 204 mounted onto
refrigerator door 128 and defining an icebox compartment 160, one
skilled in the art will appreciate that aspects of the present
subject matter may be used to create liners for different
applications. For example, a door liner may be used in different
chambers of refrigerator appliance 100, and may serve purposes
other than defining icebox compartment 160. Exemplary door liners
may even be used on other consumer appliances. Indeed, features of
the present invention may be used in any application where it is
desirable to have an injection-molded part having integral inlet
and outlet ports or ducts.
[0057] Now that the construction of refrigerator door 128 and door
liner 204 according to an exemplary embodiment has been presented,
a method of forming these parts will now be described. Such a
method may include fabricating door liner 204 as a unitary liner,
e.g., such that door liner 204 is integrally formed of a single
continuous piece of plastic, metal or other suitable material. The
outer panel 202 of refrigerator is typically cut or stamped and
formed from a structurally firm metal material such as steel,
stainless steel, painted steel aluminum, or any other suitably
rigid material. Door liner 204 is injection molded as a single,
integral piece, and defines icebox compartment 160, cooling air
inlet duct 220, and cooling air outlet duct 222. Door liner 204 is
mounted to the outer panel 202 to form refrigerator door 128 having
a hollow cavity. The cavity is then filled with insulating
foam.
[0058] Integral formation of the entire door liner 204 requires
mold tooling specifically designed to form icebox compartment 160,
as well as inlet and outlet ducts 220, 222. Once the mold pieces
are in place, the mold is injected with injection-molding grade
plastic to form a single-piece door liner. After the injected
plastic is solidified, the mold parts are removed to reveal a
single-piece door liner having integral cooling ducts.
[0059] By contrast, prior methods of forming a refrigerator door
liner have required multiple parts and a complicated assembly
process. More specifically, an icebox frame would be separately
formed by injection molding or another process. Holes would be
formed in the icebox frame to define the first end of each duct. A
perimeter liner would be separately formed and have holes punched
for defining the opposite, second end of each duct. The icebox
frame and the perimeter liner would then be joined together by,
e.g., friction welding, or by using tape or adhesive. Finally, a
duct portion would be separately formed, and the duct portion would
be inserted between the holes in the icebox frame and perimeter
liner, and then joined in a manner similar to the icebox frame and
perimeter liner. In addition to the manufacturing process being
significantly more difficult and time-consuming, the resulting door
liners frequently have small leaks through which foam might leak
during the foam insulation process. Notably, using the
above-described method of forming an integral door liner by
injection molding, manufacturing costs may be reduced and the
performance of the resulting door liner may be improved, as
discussed below.
[0060] Door liner 204 formed according to the above-described
method or exemplary embodiments may exhibit significant performance
advantages over prior, multi-part liners. From a manufacturing
perspective, fewer parts are required to be procured, stored, and
assembled. Additionally, assembly is simplified as parts do not
need to be joined, taped, sealed, or otherwise assembled. Finally,
there are fewer potential leak points where insulating foam might
escape during the insulation process. From a performance
perspective, because the door liner is produced as one part, as
opposed to several parts, the tolerances of the finished door liner
assembly can be held tighter, thus contributing to a more robust
liner. Furthermore, more design options may be available for the
refrigerator appliance due to the more precise part features. For
example, the method may permit formation of an icebox defining
integral inlet and outlet ports that may be designed for optimal
performance. Moreover, the inlet and outlet may be enhanced and
exhibit a smooth profile such that frictional losses may be
minimized and airflow performance may be optimized.
[0061] Door liners constructed in accordance with the
above-described example embodiments have demonstrated improved
performance compared to prior designs. For example, FIG. 10A
provides a plot of a measured pressure drop of cooling air as it is
circulated through icebox compartment 160 at various flow rates
compared to the pressure drop in a prior design. To determine the
system pressure drop, the difference between air pressures at two
points in the sealed cooling system 250 is determined. The first
pressure may be measured, for example, at the air handler 262
outlet, and the second pressure may be measured, for example, at
the air handler 262 inlet. As may be seen in FIG. 10A, the pressure
drop experienced by the sealed cooling system 250 is larger for
prior designs. Similarly, FIG. 10B provides a plot of a measured
pressure drop of cooling air flowing across inlet duct 220 and
outlet duct 222 of icebox compartment 160 compared to the pressure
drop in a prior multi-part assembly design. As may be seen in FIG.
10B, the pressure drop across inlet duct 220 and outlet duct 222 is
significantly lower for injection molded door liner 204, especially
at higher flow rates. A lower pressure drop means friction losses
within the sealed cooling system 250 are decreased, more cooling
air is received in icebox compartment 160, and the performance and
efficiency of the refrigerator appliance 100 is improved.
[0062] 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.
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