U.S. patent application number 16/800477 was filed with the patent office on 2021-08-26 for refrigerator with duct system to provide cold air from a freezer evaporator to an ice maker.
This patent application is currently assigned to WHIRLPOOL CORPORATION. The applicant listed for this patent is WHIRLPOOL CORPORATION. Invention is credited to Daniel W. Burlingham, Chao-Yi Chen, Milind Devle, Benjamin G. Jimenez, Rishikesh Vinayak Kulkarni, Vishal S. Marathe, Mahalingappa Mulimani, E. C. Pickles, Richard A. Spletzer, Yan Zhang.
Application Number | 20210262718 16/800477 |
Document ID | / |
Family ID | 1000004698624 |
Filed Date | 2021-08-26 |
United States Patent
Application |
20210262718 |
Kind Code |
A1 |
Burlingham; Daniel W. ; et
al. |
August 26, 2021 |
REFRIGERATOR WITH DUCT SYSTEM TO PROVIDE COLD AIR FROM A FREEZER
EVAPORATOR TO AN ICE MAKER
Abstract
A refrigerator includes a cabinet structure having a
refrigerator compartment and a freezer compartment. An evaporator
is positioned in the freezer compartment within an evaporator
housing. A door is pivotally coupled to the cabinet structure for
selectively providing access to the refrigerator compartment and
includes an ice maker. A duct assembly includes an ice maker feed
duct operably coupled to the evaporator housing at a first end, and
further coupled to the ice maker at a second end. The duct assembly
further includes an ice maker return duct operably coupled to the
ice maker at a first end and further coupled to the evaporator
housing at a second end. First and second fans are provided
in-series, wherein the first fan provides cooled air to the freezer
compartment, and the second fan provides cooled air from the first
fan to the ice maker during an ice making cycle.
Inventors: |
Burlingham; Daniel W.;
(Hartford, MI) ; Chen; Chao-Yi; (Saint Joseph,
MI) ; Devle; Milind; (Pune, IN) ; Kulkarni;
Rishikesh Vinayak; (Saint Joseph, MI) ; Mulimani;
Mahalingappa; (Pune, IN) ; Pickles; E. C.;
(Saint Joseph, MI) ; Spletzer; Richard A.; (Saint
Joseph, MI) ; Zhang; Yan; (Saint Joseph, MI) ;
Jimenez; Benjamin G.; (Durham, NC) ; Marathe; Vishal
S.; (Pune, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WHIRLPOOL CORPORATION |
BENTON HARBOR |
MI |
US |
|
|
Assignee: |
WHIRLPOOL CORPORATION
BENTON HARBOR
MI
|
Family ID: |
1000004698624 |
Appl. No.: |
16/800477 |
Filed: |
February 25, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25D 2317/061 20130101;
F25C 2400/10 20130101; F25D 17/045 20130101; F25D 2317/068
20130101; F25D 17/065 20130101; F25D 2317/067 20130101; F25C 5/22
20180101 |
International
Class: |
F25C 5/20 20060101
F25C005/20; F25D 17/06 20060101 F25D017/06; F25D 17/04 20060101
F25D017/04 |
Claims
1. A refrigerator, comprising: a cabinet structure having a
refrigerator compartment and a freezer compartment; an evaporator
positioned in the freezer compartment within an evaporator housing;
a door pivotally coupled to the cabinet structure for selectively
providing access to the refrigerator compartment, wherein the door
includes an ice maker operably coupled to the door for pivoting
movement therewith; and a duct assembly having an ice maker feed
duct operably coupled to the evaporator housing at a first end and
further coupled to the ice maker at a second end, wherein the duct
assembly further includes an ice maker return duct operably coupled
to the ice maker at a first end and further coupled to the
evaporator housing at a second end.
2. The refrigerator of claim 1, wherein the ice maker feed duct
includes a body portion disposed between the first and second ends
of the ice maker feed duct, and further wherein the body portion of
the ice maker feed duct defines a substantially linear ascending
airway.
3. The refrigerator of claim 2, wherein the ice maker return duct
includes a body portion disposed between the first and second ends
of the ice maker return duct, and further wherein the body portion
of the ice maker return duct defines substantially linear
descending airway.
4. The refrigerator of claim 1, including: a first fan fluidically
coupled to the evaporator for providing cold air from the
evaporator to the first fan.
5. The refrigerator of claim 4, including: an outlet having a first
end fluidically coupled to the first fan and a second end opening
into the freezer compartment to interconnect the first fan with the
freezer compartment, wherein the outlet includes a body portion
disposed between the first and second ends of the outlet; and an
inlet having first and second ends, wherein the inlet is
fluidically coupled to the body portion of the outlet at the first
end of the inlet.
6. The refrigerator of claim 5, including: a second fan fluidically
coupled to the second end of the inlet, wherein the second fan is
further fluidically coupled to the first end of the ice maker feed
duct.
7. The refrigerator of claim 6, wherein the second fan is
fluidically interconnected to the evaporator only through the inlet
and the outlet with the first fan disposed therebetween.
8. The refrigerator of claim 6, wherein the ice maker feed duct
includes a body portion disposed between the first and second ends
of the ice maker feed duct, and further wherein an inclined portion
of the body portion of the ice maker feed duct is linearly disposed
within a single sidewall of the cabinet structure.
9. The refrigerator of claim 8, wherein the ice maker return duct
includes a body portion disposed between the first and second ends
of the ice maker return duct, and further wherein an inclined
portion of the body portion of the ice maker return duct is
linearly disposed within a single sidewall of the cabinet
structure.
10. The refrigerator of claim 1, wherein the ice maker feed duct
and the ice maker return duct are insulated ducts.
11. A refrigerator, comprising: a cabinet structure having a
refrigerator compartment, a freezer compartment and at least one
sidewall with an interior cavity; an evaporator housing positioned
within the freezer compartment and having first and second
portions; an evaporator positioned within the first portion of an
evaporator housing; and a duct assembly having an ice maker feed
duct operably coupled to the second portion of the evaporator
housing at a first end and further coupled to an ice maker disposed
above the freezer compartment at a second end, wherein the duct
assembly further includes an ice maker return duct operably coupled
to the ice maker at a first end and further coupled to the first
portion of the evaporator housing at a second end, and further
wherein the ice maker feed duct and the ice maker return duct
include substantially linear body portions disposed within the
interior cavity of the at least one sidewall of the cabinet
structure.
12. The refrigerator of claim 11, including: a freezer compartment
fan disposed in the second portion of the evaporator housing and
fluidically coupled to the first portion of the evaporator
housing.
13. The refrigerator of claim 12, including: an ice maker fan
disposed in the second portion of the evaporator housing and
fluidically coupled to the first end of the ice maker feed
duct.
14. The refrigerator of claim 13, wherein the ice maker fan is
fluidically coupled to the freezer compartment fan in-series.
15. A refrigerator, comprising: first and second fans each having a
first side and a second side, wherein with the first and second
fans are arranged in-series with the second side of the first fan
fluidically coupled to the first side of the second fan by an
inlet; an evaporator disposed within a freezer compartment and
fluidically coupled to the first side of the first fan; an ice
maker disposed outside of the freezer compartment and fluidically
coupled to the second side of the second fan by an ice maker feed
duct; and an ice maker return duct fluidically coupled between the
ice maker and the evaporator.
16. The refrigerator of claim 15, including: a controller for
controlling the evaporator between a freezer compartment cooling
cycle and an ice making cycle, wherein the controller further
controls the first and second fans between active and at-rest
conditions.
17. The refrigerator of claim 16, wherein the first fan is in the
active condition and the second fan is in the at-rest condition
during the freezer compartment cooling cycle.
18. The refrigerator of claim 17, wherein cold air from the
evaporator is provided at a first temperature level to the ice
maker during the freezer compartment cooling cycle.
19. The refrigerator of claim 18, wherein the first fan is in the
active condition and the second fan is in the active condition
during the ice making cycle.
20. The refrigerator of claim 19, wherein cold air from the
evaporator is provided at a second temperature level to the ice
maker during the ice making cycle, and further wherein the second
temperature level is lower than the first temperature level.
Description
BACKGROUND OF THE DISCLOSURE
[0001] The present concept generally relates to a refrigeration
device, and more particularly, to a refrigeration device in the
form of a refrigerator having conduits directing cooled air from
the freezer compartment to an ice maker disposed in a refrigerator
door.
[0002] Duct systems in a refrigerator can be complex non-linear
systems that lead to increased negative pressure in a freezer
compartment which can lead to frost buildup in the freezer
compartment due to ambient air infiltration. This is particularly
noticeable when a duct system includes both a cabinet duct system
and a door duct system that interconnect to provide cold air to an
ice maker. The present concept provides a directly routed duct
system to help equalize pressure and reduce ambient air
infiltration.
SUMMARY OF THE DISCLOSURE
[0003] According to one aspect of the present disclosure, a
refrigerator includes a cabinet structure having a refrigerator
compartment and a freezer compartment. An evaporator is positioned
in the freezer compartment within an evaporator housing. A door is
pivotally coupled to the cabinet structure for selectively
providing access to the refrigerator compartment. The door includes
an ice maker operably coupled to the door for pivoting movement
therewith. A duct assembly includes an ice maker feed duct that is
operably coupled to the evaporator housing at a first end and
further coupled to the ice maker at a second end. The duct assembly
further includes an ice maker return duct operably coupled to the
ice maker at a first end and further coupled to the evaporator
housing at a second end.
[0004] According to another aspect of the present disclosure, a
refrigerator includes a cabinet structure having a refrigerator
compartment, a freezer compartment and at least one sidewall with
an interior cavity. An evaporator housing is positioned within the
freezer compartment and includes first and second portions. An
evaporator is positioned within the first portion of an evaporator
housing. A duct assembly includes an ice maker feed duct operably
coupled to the second portion of the evaporator housing at a first
end and further coupled to an ice maker disposed above the freezer
compartment at a second end. The duct assembly further includes an
ice maker return duct operably coupled to the ice maker at a first
end and further coupled to the first portion of the evaporator
housing at a second end. The ice maker feed duct and the ice maker
return duct include substantially linear body portions disposed
within the interior cavity of the at least one sidewall of the
cabinet structure.
[0005] According to yet another aspect of the present disclosure, a
refrigerator includes first and second fans each having a first
side and a second side. The first and second fans are arranged
in-series with the second side of the first fan fluidically coupled
to the first side of the second fan by an inlet. An evaporator is
disposed within a freezer compartment and fluidically coupled to
the first side of the first fan. An ice maker is disposed outside
of the freezer compartment and fluidically coupled to the second
side of the second fan by an ice maker feed duct. An ice maker
return duct is fluidically coupled between the ice maker and the
evaporator.
[0006] These and other features, advantages, and objects of the
present disclosure will be further understood and appreciated by
those skilled in the art by reference to the following
specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the drawings:
[0008] FIG. 1 is a top front perspective view of a
refrigerator;
[0009] FIG. 2 is a top rear perspective view of the refrigerator of
FIG. 1 with an exterior wrapper removed to reveal a refrigerator
compartment, a freezer compartment, an ice maker, an evaporator
housing and a duct assembly;
[0010] FIG. 3 is a top front perspective view of the duct assembly
of FIG. 2 as coupled to the ice maker and disposed within a
sidewall shown in phantom;
[0011] FIG. 4 is a rear elevation view of the refrigerator of FIG.
1 with a rear wall of the exterior wrapper removed;
[0012] FIG. 5 is a side top perspective view of the duct assembly
of FIG. 3;
[0013] FIG. 6 is a top perspective view of the evaporator housing
of FIG. 2;
[0014] FIG. 7 is a schematic illustration of an evaporator housing
connected to a freezer compartment and further connected to an
icemaker via a duct assembly;
[0015] FIG. 8 is a front elevation view of the ice maker of FIG. 3;
and
[0016] FIG. 9 is a top perspective view of the evaporator housing
of FIG. 6.
DETAILED DESCRIPTION
[0017] The present illustrated embodiments reside primarily in
combinations of method steps and apparatus components related to a
duct and fan assembly for a refrigerator. Accordingly, the
apparatus components and method steps have been represented, where
appropriate, by conventional symbols in the drawings, showing only
those specific details that are pertinent to understanding the
embodiments of the present disclosure so as not to obscure the
disclosure with details that will be readily apparent to those of
ordinary skill in the art having the benefit of the description
herein. Further, like numerals in the description and drawings
represent like elements.
[0018] For purposes of description herein, the terms "upper,"
"lower," "right," "left," "rear," "front," "vertical,"
"horizontal," and derivatives thereof shall relate to the
disclosure as oriented in FIG. 1. Unless stated otherwise, the term
"front" shall refer to the surface of the element closer to an
intended viewer, and the term "rear" shall refer to the surface of
the element further from the intended viewer. However, it is to be
understood that the disclosure may assume various alternative
orientations, except where expressly specified to the contrary. It
is also to be understood that the specific devices and processes
illustrated in the attached drawings, and described in the
following specification are simply exemplary embodiments of the
inventive concepts defined in the appended claims. Hence, specific
dimensions and other physical characteristics relating to the
embodiments disclosed herein are not to be considered as limiting,
unless the claims expressly state otherwise.
[0019] The terms "including," "comprises," "comprising," or any
other variation thereof, are intended to cover a non-exclusive
inclusion, such that a process, method, article, or apparatus that
comprises a list of elements does not include only those elements
but may include other elements not expressly listed or inherent to
such process, method, article, or apparatus. An element proceeded
by "comprises a . . . " does not, without more constraints,
preclude the existence of additional identical elements in the
process, method, article, or apparatus that comprises the
element.
[0020] Referring to the embodiment illustrated in FIG. 1, reference
numeral 10 generally designates a refrigerator having a cabinet
structure 13 with a front surface 14 opening into a refrigerator
compartment 12. The cabinet structure 13 may include a vacuum
insulated cabinet structure, as further described below. The
refrigerator compartment 12 is contemplated to be an insulated
portion of the cabinet structure 13 for storing fresh food items.
First and second doors 18, 20 are rotatably coupled to the cabinet
structure 13 near the front surface 14 thereof for selectively
providing access to the refrigerator compartment 12 by pivoting
movement between open and closed positions. In the embodiment shown
in FIG. 1, a freezer drawer 22 is configured to selectively provide
access to a freezer compartment 24 disposed below the refrigerator
compartment 12. The refrigerator 10 shown in FIG. 1 is an exemplary
embodiment of a refrigerator for use with the present concept, and
is not meant to limit the scope of the present concept in any
manner.
[0021] As further shown in FIG. 1, the first door 18 includes a
dispensing station 2 which may include one or more paddles 4, 6
which are configured to initiate the dispensing of water and/or ice
from outlets disposed within the dispensing station 2. In the
embodiment shown in FIG. 1, the dispensing station 2 is shown as
being accessible from outside of the refrigerator 10 on an exterior
portion of the first door 18, but may also be provided along any
portion of the refrigerator 10, including an interior of the
refrigerator compartment 12, for dispensing ice and/or water. The
dispensing station 2 is contemplated to be coupled to an ice maker
30 which is shown in phantom in FIG. 1. It is contemplated that the
ice maker 30 may be operably coupled to the first door 18 to
pivotally move with the first door 18 between open and closed
positions. Further, it is contemplated that the ice maker 30 may be
fixedly positioned within the refrigerator compartment 12. As
further shown in FIG. 1, the cabinet structure 13 of the
refrigerator 10 includes an exterior wrapper 32 which includes
first and second sidewalls 34, 36, a top wall 38 and a rear wall
40. The exterior wrapper 32 is contemplated to be a metal component
formed of a sheet metal material.
[0022] Referring now to FIG. 2, the refrigerator 10 is shown with
the cabinet structure 13 removed to reveal the refrigerator
compartment 12 disposed over the freezer compartment 24. The
refrigerator compartment 12 is generally defined by a refrigerator
liner 42 which includes first and second sidewalls 44, 46, a top
wall 48, a rear wall 50 and a bottom wall 52. The freezer
compartment 24 also includes a freezer liner 53 having first and
second sidewalls 54, 56, a top wall 58, a rear wall 60 and a bottom
wall 62. The refrigerator liner 42 and freezer liner 53 may be
comprised of a sheet metal material or a polymeric material. As
encapsulated by the exterior wrapper 32, the refrigerator liner 42
and the freezer liner 53 are spaced-apart from the exterior wrapper
32 to define an insulating space 66 (FIG. 4) therebetween, which
may include a vacuum insulated space. Thus, the exterior wrapper 32
and the refrigerator liner 42 and freezer liner 53 may be
interconnected by a trim breaker to define the overall cabinet
structure 13 of the refrigerator 10.
[0023] With further reference to FIG. 1, the cabinet structure 13
includes first and second sidewalls 13A and 13B. The first sidewall
13A of the cabinet structure 13 is comprised of the first sidewall
34 of the exterior wrapper 32 as spaced-apart from the first
sidewall 44 of the refrigerator liner 42 and the first sidewall 54
of the freezer liner 53. With the first sidewall 34 of the exterior
wrapper 32 spaced-apart from the first sidewall 44 of the
refrigerator liner 42 and spaced-apart from the first sidewall 54
of the freezer liner 53, an interior cavity 68 (FIGS. 3 and 4) of
the first sidewall 13A is defined therebetween. The interior cavity
68 of the first sidewall 13A of the cabinet structure 13 is part of
the insulating space 66 (FIG. 4) surrounding the refrigerator liner
42 and the freezer liner 53 and that is further surrounded or
encapsulated by the exterior wrapper 32. It is contemplated that
the second sidewall 13B is similarly formed on an opposite side of
the cabinet structure 13 relative to the first sidewall 13A. In
FIGS. 3 and 4 the combination of the first sidewall 44 of the
refrigerator liner 42 and the first sidewall 54 of the freezer
liner 53 is represented by reference numeral 35 for ease in
defining the parameters of the first sidewall 13A of the cabinet
structure 13.
[0024] With further reference to FIG. 2, an evaporator housing 64
is shown disposed on or adjacent to the rear wall 60 of the freezer
liner 53. The evaporator housing 64 houses an evaporator 80 (FIG.
4) that provides cold air to the freezer compartment 24 and the ice
maker 30. In FIG. 2, the evaporator 80 is concealed by an
evaporator housing cover 65. It is contemplated that cold air may
be drawn from the evaporator housing 64 for cooling the
refrigerator compartment 12 as well. The first sidewall 13A (FIG.
1) is positioned on the same side of the cabinet structure 13 as
the ice maker 30 and the evaporator housing 64. As positioned on
this side of the cabinet structure 13, the interior cavity 68 of
the first sidewall 13A houses a duct assembly 70 that interconnects
the ice maker 30 and an evaporator housing 64. The duct assembly 70
is configured to be concealed within the interior cavity 68 of the
first sidewall 13A, as best shown in FIG. 3. The duct assembly 70
includes an ice maker feed duct 72 having first and second ends 74,
76 with a body portion 78 disposed therebetween. The body portion
78 is a substantially liner body portion that defines an ascending
airway between the evaporator housing 64 and the ice maker 30. The
duct assembly 70 further includes an ice maker return duct 82. The
ice maker return duct 82 includes a first end 84 coupled to the ice
maker 30, and a second end 86 coupled to the evaporator housing 64.
The ice maker return duct 82 further includes a body portion 88
disposed between the first and second ends 84, 86 that defines
substantially linear descending airway between the ice maker 30 and
the evaporator housing 64. As used herein, the terms "substantial,"
"substantially," and variations thereof are intended to note that a
described feature is equal or approximately equal to a value or
description. For example, a "substantially linear" feature is
intended to denote a feature that is linear or approximately
linear. Moreover, "substantially" is intended to denote that two
values are equal or approximately equal. In some embodiments,
"substantially" may denote values within about 10% of each other,
such as within about 5% of each other, or within about 2% of each
other. As such, the substantially linear body portions 78, 88 of
the ice maker feed duct 72 and the ice maker return duct 82,
respectively, are contemplated to be substantially straight or
linear body portions that interconnect the evaporator housing 64
with the ice maker 30 in a direct and un-convoluted manner.
[0025] Referring now to FIG. 3, the duct assembly 70 is shown
disposed within the interior cavity 68 of the first sidewall 13A of
the cabinet structure 13. As configured in FIG. 3, the ice maker
feed duct 72 and the ice maker return duct 82 of the duct assembly
70 are entirely disposed within the interior cavity 68 of the first
sidewall 13A of the cabinet structure 13. The first sidewall 13A is
shown in phantom in FIG. 3 to better illustrate the position of the
duct assembly 70 within the interior cavity 68 of the first
sidewall 13A. Thus, the duct assembly 70, including ice maker feed
duct 72 and the ice maker return duct 82, is disposed within a
single sidewall, the first sidewall 13A, of the cabinet structure
13. This configuration helps to directly feed cold air from the
evaporator housing 64 to the ice maker 30. In FIG. 3, the
evaporator housing cover 65 (FIG. 2) has been removed from the
evaporator housing 64 to reveal first and second portions 64A, 64B
of the evaporator housing 64. In the second portion 64B of the
evaporator housing 64, the evaporator 80 (FIG. 4) is disposed and
concealed in the view of FIG. 3 by an evaporator plate 81. In the
first portion 64A of the evaporator housing 64, first and second
fans 100, 102 are shown. The first fan 100 is configured to feed
cold air to the freezer compartment 24 during a freezer compartment
cooling cycle. As such, the first fan 100 may be referred to herein
as a freezer compartment fan. The first fan 100 is connected
in-series to the second fan 102, as further described below. Thus,
the first fan 100 provides cold air not only to the freezer
compartment 24, but also provides cold air from the evaporator 80
to the second fan 102 as well. The second fan 102 provides cold air
from the first fan 100 to the ice maker 30 via the duct assembly 70
during an ice making cycle. As such, the second fan 102 may be
referred to herein as an ice maker fan. Thus, the first and second
fans 100, 102 are operable between active and at-rest conditions,
wherein the fans 100, 102 are running in the active condition and
are not running in the at-rest condition. The condition of the
first and second fans 100, 102 is controlled by a controller of the
refrigerator 10, as further described below, which also controls
the various cycles of the refrigerator 10.
[0026] As further shown in FIG. 3, the ice maker 30 includes first
and second portions 30A, 30B. As illustrated, the ice maker feed
duct 72 is interconnected between the evaporator housing 64, at the
first portion 64A thereof, at the first end 74 of the ice maker
feed duct 72, and the ice maker 30, at the first portion 30A
thereof, at the second end 76 of the ice maker feed duct 72. As
further illustrated in FIG. 3, the ice maker return duct 82 is
interconnected between the ice maker 30, at the second portion 30B
thereof, at the first end 84 of the ice maker return duct 82, and
evaporator housing 64, at the second portion 64B thereof, at the
second end 86 of the ice maker return duct 82. Thus, it is
contemplated that the second fan 102 supplies cold air from the
evaporator housing 64 to the ice maker 30 via the ice maker feed
duct 72 of the duct assembly 70. The cold air powered by the second
fan 102 is fed into the first portion 30A of the ice maker 30 by
the ice maker feed duct 72. It is contemplated that ice is made in
the first portion 30A of the ice maker 30. Cold air remaining from
the ice making process is returned to the second portion 64B of the
evaporator housing 64 by the ice maker return duct 82 4 recycling.
In this way, the ice maker return duct 82 provides cold air to the
evaporator housing 64 near the evaporator 80, such that the
evaporator 80 can use the cold air leftover from an ice making
process when providing cold air to the first fan 100. This results
in an overall energy savings for the cold air producing process of
the evaporator 80. Both the ice maker feed duct 72 and the ice
maker return duct 82 are contemplated to be insulated ducts, as
they are configured to carry much colder air as compared to cold
air provided to the refrigerator compartment 12 (FIGS. 1-2). The
ice maker feed duct 72 and the ice maker return duct 82 are
contemplated to be insulated by a gas impervious barrier having an
insulating material, such that the super cooled air carried in the
ice maker feed duct 72 and the ice maker return duct 82 is not
diffused into other components of the refrigerator 10 along the
travel path between the evaporator housing 64 and the ice maker
30.
[0027] Referring now to FIG. 4, the duct assembly 70 is shown
disposed within the interior cavity 68 of the first sidewall 13A of
the cabinet structure 13. As configured in FIG. 4, the ice maker
feed duct 72 and the ice maker return duct 82 of the duct assembly
70 are entirely disposed within the interior cavity 68 of the first
sidewall 13A of the cabinet structure 13. Thus, as noted above, the
duct assembly 70 is disposed entirely within the first sidewall 13A
of the cabinet structure 13 given the narrow profile of the duct
assembly 70. The ice maker feed duct 72 is positioned vertically
above the ice maker return duct 82, such that in the view of FIG.
4, the ice maker return duct 82 is largely concealed by the ice
maker feed duct 72. This vertical overlapping configuration of the
ice maker feed duct 72 and the ice maker return duct 82 helps to
keep the profile of the overall duct assembly 70 narrow for
reception within the interior cavity 68 of the first sidewall 13A
of the cabinet structure 13.
[0028] Referring now to FIG. 5, the duct assembly 70 is shown with
the ice maker feed duct 72 and the ice maker return duct 82
positioned with the respective body portions 78, 88 thereof in a
substantially parallel relationship. As noted above, the ice maker
feed duct 72 is positioned vertically above the ice maker return
duct 82 in assembly. Also noted above, the respective body portions
78, 88 of the ice maker feed duct 72 and the ice maker return duct
82 are substantially linear to define direct has of airflow through
the body portions 78, 88 as respectively indicated by arrows 78A,
88A. With specific reference to the ice maker feed duct 72, the
body portion 78 thereof is an inclined body portion that upwardly
ascends from the first end 74 to the second end 76 in a
substantially linear manner. This inclined body portion 78 results
in an inclined airflow, as indicated by arrow 78A, through the ice
maker feed duct 72. With specific reference to the ice maker return
duct 82, the body portion 88 thereof is an inclined body portion
that downwardly ascends from the first end 84 to the second end 86
in a substantially linear manner. This inclined body portion 88
results in an inclined airflow, as indicated by arrow 88A, through
the ice maker return duct 82. As used herein, the term
"substantially linear" indicates that the body portions 78, 88 of
the ice maker feed duct 72 and the ice maker return duct 82,
respectively, are substantially straight or straight body portions
that directly interconnect the evaporator housing 64 with the ice
maker 30. As shown in FIG. 5, the first ends 74, 84 and the second
ends 76, 86 include some curved portions that outwardly offset the
body portions 78, 88, but the body portions 78, 88 themselves are
substantially linear. As such, it is contemplated that the body
portions 78, 88 of the ice maker feed duct 72 and the ice maker
return duct 82, respectively, are 90% linear, 95% linear or more
relative to the inclined portions of the body portions 78, 88 that
are disposed within the interior cavity 68 of the first sidewall
13A of the cabinet structure 13, as shown in FIG. 3. Thus, the body
portion 78 of the ice maker feed duct 72 defines a substantially
linear ascending airway from the evaporator housing 64 to the ice
maker 30. Similarly, the body portion 88 of the ice maker return
duct 82 defines a substantially linear descending airway from the
ice maker 30 to the evaporator housing 64. Thus, the inclined
portion of the body portions 78, 88 of the ice maker feed duct 72
and ice maker return duct 82 are both linearly disposed within a
single sidewall, the first sidewall 13A, of the cabinet structure
13.
[0029] The substantially linear ducts 72, 82 of the duct assembly
70 connects the source of cold air (the freezer evaporator 80)
directly to the ice maker 30. This direct connection between the
evaporator housing 64 and the ice maker 30 eliminates the need for
door ducts which would introduce branching to the substantially
linear duct design. In this way, the total length of the airways
defined by the ice maker feed duct 72 and the ice maker return duct
82 going from the evaporator 80 to the ice maker 30 is greatly
reduced. Also, the air resistance to reach the ice maker 30 is
greatly reduced because cold air traveling along the airflow path
indicated by arrow 78A does not have to turn in a torturous path
from cabinet ducts to door ducts. As a result, the pressure drop
across the ducts 72, 82 is reduced by more than 50% at the same
airflow cfm rate. Due to lesser pressure drop across the ducts 72,
82, the pressure in the freezer compartment 24 increases from
-0.04'' of water to less than -0.02'' of water. Thus, the
infiltration inside freezer compartment 24 from the ambient air
surrounding the same is greatly reduced due to reduction in
negative pressure in the freezer compartment 24. With the current
linear duct assembly 70, test results show no frost formation in
the freezer compartment 24 at standard fan speeds. Frost formation
is measured on the Leichert's Scale ranging from 0, which indicates
a completely clean or frost free environment, to 7, which is
indicates a frost accumulation of more than a four square inch
area. Based on simulations conducted with standard ducts having
indirect nonlinear pathways, an equation was created to predict the
frost formation based on the Leichert's Scale. The results of the
equation show the Leichert's Scale scale moving from a range of
about 4-7 on the Leichert's Scale in the non-linear duct
assemblies, to about 0-2 on the Leichert's Scale with the
substantially linear ducts 72, 82 of the present concept.
[0030] Referring now to FIG. 6, the first fan 100 includes first
and second sides 100A, 100B which respectively indicate intake and
output sides of the first fan 100. Similarly, the second fan 102
includes first and second sides 102A, 102B which respectively
indicate intake and output sides of the second fan 102. As noted
above, the first and second fans 100, 102 are arranged in-series
with the second side 100B of the first fan 100 being fluidically
coupled to the first side 102A of the second fan 102 by an inlet
110. Specifically, the first side 100A of the first fan 100 opens
into a spacing 103 that fluidically interconnects the first fan 100
and the evaporator 80 to provide cold air from the evaporator 80 to
the first side 100A of the first fan 100. It is contemplated that
the spacing 103 may be a direct duct member that interconnects the
first fan 100 with the evaporator 80. It is also contemplated that
the spacing 103 may be defined by the evaporator housing cover 65
(FIG. 2), such that the spacing 103 is an open spacing between the
first side 100A of the first fan 100 and the evaporator 80. The
second side 100B of the first fan 100 opens into an outlet 104 for
providing cooled air to the freezer compartment 24. Specifically,
the outlet 104 includes first and second ends 105A, 105B and a body
portion 105 disposed between the first and second ends 105A, 105B.
The first end 105A of the outlet 104 is fluidically coupled to the
second side 100B of the first fan 100. The second end 105B of the
outlet 104 opens into the freezer compartment 24 to fluidically
interconnect the first fan 100 with the freezer compartment 24. As
further shown in FIG. 6, the inlet 110 includes first and second
ends 112A, 112B have a body portion 112 disposed therebetween. The
first end 112A of the inlet 110 is fluidically coupled to the body
portion 105 of the outlet 104. The second end 112B of the inlet 110
is fluidically coupled with the second fan 102 at the first side
102A of the second fan 102. As further shown in FIG. 6, the second
side 102B of the second fan 102 is fluidically coupled to the first
end 74 of the ice maker feed duct 72. Thus, the first and second
fans 100, 102 are configured in-series wherein the first fan 100 is
the only fan directly connected to the evaporator 80 through the
spacing 103, and the second fan 102 is fluidically interconnected
with the evaporator 80 only through the inlet 110 and outlet 104
with the first fan 100 disposed therebetween. Thus, the first fan
100 is the only fan that can draw cooled air from the evaporator 80
directly, as the second fan 102 is only coupled to the evaporator
80 through the first fan 100.
[0031] As used herein, the terms "fluidically coupled",
"fluidically connected" or "fluidically interconnected" indicates
that two or more structures are connected to one another in such a
way as to provide for fluid airflow between the two or more
structures. Said differently, an airway interconnects the two or
more structures, such as the duct assembly 70 fluidically
interconnecting the ice maker 30 and the evaporator housing 64.
Also as used herein, the term "in-series" indicates two or more
structures that are serially aligned along an airway, such as the
first and second fans 100, 102.
[0032] Referring now to FIG. 7, it is contemplated that a
controller 120 for the refrigerator 10 is provided that controls
both the first fan 100 and the second fan 102, such that they can
run oscillate between the active and at-rest conditions during
distinct cooling cycles (i.e. a freezer compartment cooling cycle,
and an ice making cycle). The controller 120 is shown in FIG. 7 as
being operably coupled to the first and second fans 100, 102 and
the evaporator 80, for controlling the same. Specifically, the
first and second fans 100, 102 are controlled by the controller 120
between the active and at-rest conditions, while the evaporator 80
can be controlled by the controller 120 to provide various
temperature levels of cold air as needed per a specific
refrigerator cycle. It is consummated that the controller 120 can
be positioned at any portion within the refrigerator 10, so long as
the controller 120 is electronically coupled with the first and
second fans 100, 102 and the evaporator 80. It is contemplated that
the first fan 100 will be in the active condition and will run
during a freezer compartment cooling cycle with cold air
temperatures provided to the freezer compartment 24 at a first
temperature level via the evaporator 80. It is contemplated that
the second fan 102 will be in the at-rest condition and not run
during the freezer compartment cooling cycle, so as not to
unnecessarily draw air intended for the freezer compartment 24 to
the ice maker 30. However, as noted above, the second fan 102 is
fluidically coupled to the first fan 100 which is fluidically
coupled to the evaporator 80. Thus, even when the second fan 102 is
in the at-rest condition, cold air from the evaporator 80 will be
propelled by the first fan 100 to not only the freezer compartment
24 via outlet 104, but cold air from the evaporator 80 will also be
propelled by the first fan 100 to the inlet 110. As noted above,
the inlet 110 is fluidically coupled to the second fan 102 which is
fluidically coupled to the duct assembly 70 which is fluidically
coupled to the ice maker 30. In this way, cold air from the
evaporator 80 is provided to the ice maker 30 by the first fan 100
when the first fan 100 is in the active condition during a freezer
compartment cooling cycle, even though the second fan 102 is in the
at-rest condition. The cold air from the evaporator 80 is provided
to the ice maker 30 by the first fan 100 during a freezer
compartment cooling cycle a level sufficient to keep already formed
and stored ice in the ice maker 30 from melting.
[0033] Further, it is contemplated that the second fan 102 will be
in the active condition and will run during an ice making cycle
with temperatures provided at a second temperature level via the
evaporator 80. It is contemplated that the second temperature level
of cold air provided by the evaporator 80 is less than the first
temperature level. The second temperature level is contemplated to
be a temperature level below freezing to provide appropriate
temperatures of cooled air for making ice in the ice maker 30. It
is contemplated that the first fan 100 will also be in the active
condition and will run during the ice making cycle along with the
second fan 102. As the first fan 100 and the second fan 102 are
connected in-series, the first fan 100 will assist the second fan
102 in providing cooled air to the ice maker 30, rather than having
the first fan 100 compete with the second fan 102 for cooled air
from the evaporator 80.
[0034] With further reference to FIG. 7, the first fan 100 is
configured for rotation along the path as indicated by arrow R1
when the first fan 100 is in the active condition. Similarly, the
second fan 102 is configured for rotation along the path as
indicated by arrow R2 when the second fan 102 is in the active
condition. As noted above, the first and second fans 100, 102 are
arranged in-series with the second side 100B of the first fan 100
being fluidically coupled to the first side 102A of the second fan
102 by the inlet 110, as shown in FIG. 6. In the schematic view of
FIG. 7, the first fan 100 opens into the spacing 103 that
fluidically interconnects the first fan 100 with the evaporator 80
to provide cold air from the evaporator 80 to the first fan 100.
The first fan 100 directs cold air from the evaporator 80 into the
outlet 104 for providing cooled air to the freezer compartment 24
via venting apertures 106 that are contemplated to open into the
freezer compartment 24 to fluidically interconnect the first fan
100 with the freezer compartment 24. The body portion 105 of the
outlet 104 is further coupled, in a fluidic manner, to the first
end 112A of the inlet 110. As noted above, and shown schematically
in FIG. 7, the second end 112B of the inlet 110 is fluidically
coupled with the second fan 102. While only the first fan 100 is
fluidically coupled to the evaporator 80 in a direct manner, cold
air from the evaporator 80 is provided to the ice maker 30 during a
freezer compartment cooling cycle of the refrigerator 10. Relative
airflow to the freezer compartment 24 is indicated in FIG. 7 by the
four arrows emanating from the first fan 100 towards the venting
apertures 106 within the outlet 104. Further, relative airflow to
the inlet 110 is indicated in FIG. 7 by the arrow emanating from
the first fan 100 towards the inlet 110. Thus, a majority of the
cold air from the evaporator 80 is provided to the freezer
compartment 24 during a freezer compartment cooling cycle of the
refrigerator 10 as powered by the first fan 100 alone. A smaller
portion of cold air is provided to the ice maker 30 through the
inlet 110 in the duct assembly 70 during the freezer compartment
cooling cycle as powered by the first fan 100 in the active
condition, even when the second fan 102 is in the at-rest
condition. As noted above, this portion of cold air provided by the
first fan 100 to the ice maker 30 during a freezer compartment
cooling cycle is enough to keep ice stored in the ice maker 30 from
melting.
[0035] Referring now to FIG. 8, the ice maker 30 is shown with the
first end 74 of the ice maker feed duct 72 shown feeding cold air
into the first portion 30A of the ice maker 30 along an airflow
path as indicated by arrow AF1. The cold air provided to the first
portion 30A of the ice maker 30 via the ice maker feed duct 72 is
used to create ice within the ice maker 30. Cold air then travels
from the first portion 30A of the ice maker 30 to the second
portion 30B of the ice maker 30 along the airflow path indicated by
arrow AF2. Cold air then exits the second portion 30B of the ice
maker 30 along the airflow path indicated by arrow AF3 to return to
the evaporator housing 64 for recycling via the ice maker return
duct 82.
[0036] Referring now to FIG. 9, the evaporator housing 64 is shown
with the evaporator plate 81 surrounding the evaporator 80 which
opens into the spacing 103 disposed adjacent to the first side 100A
of the first fan 100. In this way, the spacing 103 defines an
airway from the evaporator 80 for cold air to fluidically connect
with the first side 100A of the first fan 100 for intake and
distribution into the freezer compartment 24, as powered by the
first fan 100, and distribution into the ice maker 30, as powered
by the first fan 100 alone or in combination with the second fan
102 in a manner as described above. As shown in FIG. 9, the second
fan 102 includes a housing 122 that further includes a mounting
flange 124. The housing 122 surrounds and insulates the second fan
102 from the spacing 103, such that the second fan 102 is not in
direct fluid communication with the spacing 103 and the cold air
from the evaporator 80. The mounting flange 124 of the housing 122
is configured to couple to the rear wall 40 (FIG. 1) of the
exterior wrapper 32, or the evaporator housing cover 65 (FIG.
2).
[0037] According to one aspect of the present disclosure, a
refrigerator includes a cabinet structure having a refrigerator
compartment and a freezer compartment. An evaporator is positioned
in the freezer compartment within an evaporator housing. A door is
pivotally coupled to the cabinet structure for selectively
providing access to the refrigerator compartment. The door includes
an ice maker operably coupled to the door for pivoting movement
therewith. A duct assembly includes an ice maker feed duct that is
operably coupled to the evaporator housing at a first end and
further coupled to the ice maker at a second end. The duct assembly
further includes an ice maker return duct operably coupled to the
ice maker at a first end and further coupled to the evaporator
housing at a second end.
[0038] According to another aspect of the present disclosure, the
ice maker feed duct includes a body portion disposed between the
first and second ends of the ice maker feed duct, and further
wherein the body portion of the ice maker feed duct defines a
substantially linear ascending airway.
[0039] According to another aspect of the present disclosure, the
ice maker return duct includes a body portion disposed between the
first and second ends of the ice maker return duct, and further
wherein the body portion of the ice maker return duct defines a
substantially linear ascending airway.
[0040] According to another aspect of the present disclosure, a
first fan fluidically coupled to the evaporator housing for
providing cold air from the evaporator to the first fan.
[0041] According to another aspect of the present disclosure, an
outlet having a first end fluidically coupled to the first fan and
a second end opening into the freezer compartment to interconnect
the first fan with the freezer compartment, wherein the outlet
includes a body portion disposed between the first and second ends
of the outlet and an inlet having first and second ends, wherein
the inlet is fluidically coupled to the body portion of the outlet
at the first end of the inlet.
[0042] According to another aspect of the present disclosure, a
second fan fluidically coupled between the second end of the inlet,
wherein the second fan is further fluidically coupled to the first
end of the ice maker feed duct.
[0043] According to another aspect of the present disclosure, the
second fan is fluidically interconnected to the evaporator only
through the inlet and outlet with the first fan disposed
therebetween.
[0044] According to another aspect of the present disclosure, the
ice maker feed duct includes a body portion between the first and
second ends of the ice maker feed duct, and further wherein an
inclined portion of the body portion of the ice maker feed duct is
linearly disposed within a single sidewall of the cabinet
structure.
[0045] According to another aspect of the present disclosure, the
ice maker return duct includes a body portion disposed between the
first and second ends of the ice maker return duct, and further
wherein an inclined portion of the body portion of the ice maker
return duct is linearly disposed within a single sidewall of the
cabinet structure.
[0046] According to another aspect of the present disclosure, the
ice maker feed duct and the ice maker return duct are insulated
ducts.
[0047] According to another aspect of the present disclosure, a
refrigerator includes a cabinet structure having a refrigerator
compartment, a freezer compartment and at least one sidewall with
an interior cavity. An evaporator housing is positioned within the
freezer compartment and includes first and second portions. An
evaporator is positioned within the first portion of an evaporator
housing. A duct assembly includes an ice maker feed duct operably
coupled to the second portion of the evaporator housing at a first
end and further coupled to an ice maker disposed above the freezer
compartment at a second end. The duct assembly further includes an
ice maker return duct operably coupled to the ice maker at a first
end and further coupled to the first portion of the evaporator
housing at a second end. The ice maker feed duct and the ice maker
return duct include substantially linear body portions disposed
within the interior cavity of the at least one sidewall of the
cabinet structure.
[0048] According to another aspect of the present disclosure, a
freezer compartment fan disposed in the second portion of the
evaporator housing and fluidically coupled to the first portion of
the evaporator housing.
[0049] According to another aspect of the present disclosure, an
ice maker fan disposed in the second portion of the evaporator
housing and fluidically coupled to the first end of the ice maker
feed duct.
[0050] According to another aspect of the present disclosure, the
ice maker fan is fluidically coupled to the freezer compartment fan
in-series.
[0051] According to yet another aspect of the present disclosure, a
refrigerator includes first and second fans each having a first
side and a second side. The first and second fans are arranged
in-series with the second side of the first fan fluidically coupled
to the first side of the second fan by an inlet. An evaporator is
disposed within a freezer compartment and fluidically coupled to
the first side of the first fan. An ice maker is disposed outside
of the freezer compartment and fluidically coupled to the second
side of the second fan by an ice maker feed duct. An ice maker
return duct is fluidically coupled between the ice maker and the
evaporator.
[0052] According to another aspect of the present disclosure, a
controller for controlling the evaporator between a freezer
compartment cooling cycle and an ice making cycle, wherein the
controller further controls the first and second fans between
active and at-rest conditions.
[0053] According to another aspect of the present disclosure, the
first fan is in the active condition and the second fan is in the
at-rest condition during the freezer compartment cooling cycle.
[0054] According to another aspect of the present disclosure, cold
air from the evaporator is provided at a first temperature level to
the ice maker during the freezer compartment cooling cycle.
[0055] According to another aspect of the present disclosure, the
first fan is in the active condition and the second fan is in the
active condition during the ice making cycle.
[0056] According to another aspect of the present disclosure, cold
air from the evaporator is provided at a second temperature level
to the ice maker during the ice making cycle, and further wherein
the second temperature level is lower than the first temperature
level.
[0057] It will be understood by one having ordinary skill in the
art that construction of the described disclosure and other
components is not limited to any specific material. Other exemplary
embodiments of the disclosure disclosed herein may be formed from a
wide variety of materials, unless described otherwise herein.
[0058] For purposes of this disclosure, the term "coupled" (in all
of its forms, couple, coupling, coupled, etc.) generally means the
joining of two components (electrical or mechanical) directly or
indirectly to one another. Such joining may be stationary in nature
or movable in nature. Such joining may be achieved with the two
components (electrical or mechanical) and any additional
intermediate members being integrally formed as a single unitary
body with one another or with the two components. Such joining may
be permanent in nature or may be removable or releasable in nature
unless otherwise stated.
[0059] It is also important to note that the construction and
arrangement of the elements of the disclosure as shown in the
exemplary embodiments is illustrative only. Although only a few
embodiments of the present innovations have been described in
detail in this disclosure, those skilled in the art who review this
disclosure will readily appreciate that many modifications are
possible (e.g., variations in sizes, dimensions, structures, shapes
and proportions of the various elements, values of parameters,
mounting arrangements, use of materials, colors, orientations,
etc.) without materially departing from the novel teachings and
advantages of the subject matter recited. For example, elements
shown as integrally formed may be constructed of multiple parts or
elements shown as multiple parts may be integrally formed, the
operation of the interfaces may be reversed or otherwise varied,
the length or width of the structures and/or members or connector
or other elements of the system may be varied, the nature or number
of adjustment positions provided between the elements may be
varied. It should be noted that the elements and/or assemblies of
the system may be constructed from any of a wide variety of
materials that provide sufficient strength or durability, in any of
a wide variety of colors, textures, and combinations. Accordingly,
all such modifications are intended to be included within the scope
of the present innovations. Other substitutions, modifications,
changes, and omissions may be made in the design, operating
conditions, and arrangement of the desired and other exemplary
embodiments without departing from the spirit of the present
innovations.
[0060] It will be understood that any described processes or steps
within described processes may be combined with other disclosed
processes or steps to form structures within the scope of the
present disclosure. The exemplary structures and processes
disclosed herein are for illustrative purposes and are not to be
construed as limiting.
* * * * *