Method of Cooling a Deli Pan in a Refrigerator Appliance

The present subject matter relates generally to refrigerator appliances, and more particularly to methods for cooling a deli pan in a refrigerator appliance.

Refrigerator appliances generally include a cabinet that defines a chilled chamber for receipt of food articles for storage. In addition, refrigerator appliances include one or more doors rotatably hinged to the cabinet to permit selective access to food items stored in chilled chamber(s). The refrigerator appliances can also include various storage components mounted within the chilled chamber and designed to facilitate storage of food items therein. Such storage components can include racks, bins, shelves, or drawers that receive food items and assist with organizing and arranging of such food items within the chilled chamber.

Conventional refrigerators may include a deli pan positioned within the fresh food compartment. Common means for cooling the deli pan include drawing air from an evaporator plenum through a dedicated deli supply duct using an auxiliary fan and directing it into the deli pan. However, two primary problems occur with this airflow configuration when the deli fan is on. First, the deli supply airflow creates a parallel branch that redirects airflow, meaning the fresh food compartment receives one volumetric flow rate of air when the deli fan is off and a lower flow rate when the deli fan is on, negatively affecting temperature gradient and the cooling efficiency of the fresh food compartment. Second, there is undesirable mixing between the fresh food compartment and the deli supply duct where the deli fan pulls warm air from the fresh food compartment into the desired stream from the evaporator, thereby driving warmer, wetter air into the deli pan, which is not desirable.

Accordingly, a refrigerator appliance with an improved cooling system would be useful. More particularly, a cooling system that effectively regulates the flow of cool air through the fresh food compartment and the deli pan would be particularly beneficial.

Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In one exemplary embodiment, a refrigerator appliance is provided including a cabinet, a chilled chamber defined within the cabinet, an auxiliary compartment positioned within the chilled chamber, an evaporator duct containing an evaporator, an evaporator fan for selectively urging a flow of primary air through the evaporator duct and into the chilled chamber, an auxiliary duct providing fluid communication between the evaporator duct and the auxiliary compartment, an auxiliary fan for selectively urging a flow of auxiliary air from the evaporator duct, through the auxiliary duct, and into the auxiliary compartment, and a controller in operative communication with the evaporator fan and the auxiliary fan. The controller is configured to operate the evaporator fan at a first speed to provide the flow of primary air into the chilled chamber, receive a request to cool the auxiliary compartment, operate the auxiliary fan to urge the flow of auxiliary air into the auxiliary compartment, and operate the evaporator fan at a second speed, the second speed being higher than the first speed.

In another exemplary embodiment, a method of operating a refrigerator appliance is provided. The refrigerator appliance includes a chilled chamber, an auxiliary compartment positioned within the chilled chamber, an evaporator duct containing an evaporator, an evaporator fan for selectively urging a flow of primary air through the evaporator duct and into the chilled chamber, an auxiliary duct providing fluid communication between the evaporator duct and the auxiliary compartment, and an auxiliary fan for selectively urging a flow of auxiliary air from the evaporator duct, through the auxiliary duct, and into the auxiliary compartment. The method includes operating the evaporator fan at a first speed to provide the flow of primary air into the chilled chamber, receiving a request to cool the auxiliary compartment, operating the auxiliary fan to urge the flow of auxiliary air into the auxiliary compartment, and operating the evaporator fan at a second speed, the second speed being higher than the first speed.

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.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”).

Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. For example, the approximating language may refer to being within a 10 percent margin.

provides a perspective view of a refrigerator applianceaccording to an exemplary embodiment of the present subject matter. Refrigerator applianceincludes a housing or cabinetthat extends between a topand a bottomalong a vertical direction V, between a first sideand a second sidealong a lateral direction L, and between a front sideand a rear sidealong a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular to one another and form an orthogonal direction system.

Cabinetdefines chilled chambers for receipt of food items for storage. In particular, cabinetdefines fresh food chamberpositioned at or adjacent topof cabinetand a freezer chamberarranged at or adjacent bottomof cabinet. As such, refrigerator applianceis 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, a side-by-side style refrigerator appliance, or a single door refrigerator appliance. Moreover, aspects of the present subject matter may be applied to other appliances as well, such as other appliances including fluid dispensers. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular appliance or configuration.

Refrigerator doorsare rotatably hinged to an edge of cabinetfor selectively accessing fresh food chamber. In addition, a freezer dooris arranged below refrigerator doorsfor selectively accessing freezer chamber. Freezer dooris coupled to a freezer drawer (not shown) slidably mounted within freezer chamber. To prevent leakage of cool air, refrigerator doors, freezer door, and/or cabinetmay define one or more sealing mechanisms (e.g., rubber gaskets, not shown) at the interface where the doors,meet cabinet. It should be appreciated that doors having a different style, position, or configuration are possible within the scope of the present subject matter.

provides a perspective view of refrigerator applianceshown with refrigerator doorsin the open position. As shown in, various storage components are mounted within fresh food chamberto facilitate storage of food items therein as will be understood by those skilled in the art. In particular, the storage components may include binsand shelves. Each of these storage components are configured for receipt of food items (e.g., beverages and/or solid food items) and may assist with organizing such food items. As illustrated, binsmay be mounted on refrigerator doorsor may slide into a receiving space in fresh food chamber. It should be appreciated that the illustrated storage components are used only for the purpose of explanation and that other storage components may be used and may have different sizes, shapes, and configurations.

Referring again to, a dispensing assemblywill be described according to exemplary embodiments of the present subject matter. Although several different exemplary embodiments of dispensing assemblywill be illustrated and described, similar reference numerals may be used to refer to similar components and features. Dispensing assemblyis generally configured for dispensing liquid water and/or ice. Although an exemplary dispensing assemblyis illustrated and described herein, it should be appreciated that variations and modifications may be made to dispensing assemblywhile remaining within the present subject matter.

Dispensing assemblyand its various components may be positioned at least in part within a dispenser recessdefined on one of refrigerator doors. In this regard, dispenser recessis defined on a front sideof refrigerator appliancesuch that a user may operate dispensing assemblywithout opening refrigerator door. In addition, dispenser recessis positioned at a predetermined elevation convenient for a user to access ice and enabling the user to access ice without the need to bend-over. In the exemplary embodiment, dispenser recessis positioned at a level that approximates the chest level of a user.

Dispensing assemblyincludes an ice dispenserincluding a discharging outletfor discharging ice from dispensing assembly. An actuating mechanism, shown as a paddle, is mounted below discharging outletfor operating ice or water dispenser. In alternative exemplary embodiments, any suitable actuating mechanism may be used to operate ice dispenser. For example, ice dispensercan include a sensor (such as an ultrasonic sensor) or a button rather than the paddle. Discharging outletand actuating mechanismare an external part of ice dispenserand are mounted in dispenser recess. By contrast, refrigerator doormay define an icebox compartment() housing an icemaker and an ice storage bin (not shown) that are configured to supply ice to dispenser recess.

A control panelis provided for controlling the mode of operation. For example, control panelincludes one or more selector inputs, such as knobs, buttons, touchscreen interfaces, etc., 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. In addition, inputsmay be used to specify a fill volume or method of operating dispensing assembly. In this regard, inputsmay be in communication with a processing device or controller. Signals generated in controlleroperate refrigerator applianceand dispensing assemblyin response to selector inputs. Additionally, a display, such as an indicator light or a screen, may be provided on control panel. Displaymay be in communication with controller, and may display information in response to signals from controller.

As used herein, “processing device” or “controller” may refer to one or more microprocessors or semiconductor devices and is not restricted necessarily to a single element. The processing device can be programmed to operate refrigerator appliance, dispensing assemblyand other components of refrigerator appliance. The processing device may include, or be associated with, one or more memory elements (e.g., non-transitory storage media). In some such embodiments, the memory elements include electrically erasable, programmable read only memory (EEPROM). Generally, the memory elements can store information accessible processing device, including instructions that can be executed by processing device. Optionally, the instructions can be software or any set of instructions and/or data that when executed by the processing device, cause the processing device to perform operations.

Referring again briefly to, according to an exemplary embodiment, cabinetalso defines a mechanical compartmentat or near the bottomof the cabinetfor receipt of a hermetically sealed cooling system. In general, sealed cooling systemis configured for transporting heat from the inside of refrigerator applianceto the outside (e.g., by executing a vapor-compression cycle or another suitable refrigeration cycle). As is generally understood by those of skill in the art, the hermetically sealed systemcontains a working fluid, e.g., refrigerant, which flows between various heat exchangers of the sealed systemwhere the working fluid changes phases while transferring thermal energy.

In this regard, as understood by one having ordinary skill in the art, sealed systemmay include a compressor, a condenser, an expansion device, and one or more evaporators (e.g., such as evaporator) connected in series by a fluid conduit that is charged with a refrigerant. Within sealed system, refrigerant flows into the compressor, which operates to increase the pressure of the refrigerant. This compression of the refrigerant raises its temperature, which is lowered by passing the refrigerant through the condenser. Within the condenser, heat exchange with ambient air takes place so as to cool the refrigerant. A condenser fan may be used to pull air across the condenser, so as to provide forced convection for a more rapid and efficient heat exchange between the refrigerant within the condenser and the ambient air. Thus, as will be understood by those skilled in the art, increasing air flow across the condenser can, e.g., increase the efficiency of the condenser by improving cooling of the refrigerant contained therein.

An expansion device (e.g., an electronic expansion valve, capillary tube, or other restriction device) receives refrigerant from the condenser. From the expansion device, the refrigerant enters the evaporator. Upon exiting the expansion device and entering the evaporator, the refrigerant drops in pressure. Due to the pressure drop and/or phase change of the refrigerant, the evaporatoris relatively cool. An evaporator fan is typically provided at each the evaporator, e.g., to force air across and around the at least one evaporator to transfer thermal energy from the air to the evaporator (and more particularly, to the working fluid or refrigerant therein).

In this manner, a flow of cooling air exits the evaporatorand may be distributed to one or more of the chilled chambersand/or. Specifically, one or more ducts may extend between the mechanical compartmentand the chilled chambersand/orto provide fluid communication therebetween, e.g., to provide the chilled air from the hermetically sealed cooling system, e.g., from an evaporator thereof, to one or more of the chilled chambersand/or.

The sealed systemdescribed herein is provided by way of example only. Thus, it is within the scope of the present subject matter for other configurations of the refrigeration system to be used as well. For example, according to alternative embodiments, sealed systemmay include additional components, e.g., at least one additional evaporator, compressor, expansion device, and/or condenser. For example, refrigerator appliancemay have two or more split evaporators, e.g., one dedicated primarily to cooling fresh food chamberand one dedicated primarily to cooling freezer chamber. In addition, alternative plumbing configurations, valves, and flow regulators may be used to route refrigerant throughout sealed system.

In some embodiments, refrigerator appliancealso includes one or more sensors that may be used to facilitate improved operation of refrigerator appliance, such as described below. For example, in order to obtain temperature measurements within one or more chilled chambers,(or regions/zones within chilled chambers,), refrigerator appliancemay include a plurality of temperature sensors (not shown). Controllermay be communicatively coupled with the temperature sensors, may receive signals from these temperature sensors that correspond to the temperature of an atmosphere or air within their respective locations, and may implement responsive action, e.g., by directing more or less cooling air toward that region or chamber.

As used herein, “temperature sensor” or the equivalent is intended to refer to any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, the temperature sensors may be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, etc. In addition, the temperature sensors may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and/or indicative of the temperature of the air surrounding the temperature sensors. Although exemplary positioning of temperature sensors is described and illustrated herein, it should be appreciated that refrigerator appliancemay include any other suitable number, type, and position of temperature and/or other sensors according to alternative embodiments.

Referring still to, a schematic diagram of an external communication systemwill be described according to an exemplary embodiment of the present subject matter. In general, external communication systemis configured for permitting interaction, data transfer, and other communications between refrigerator applianceand one or more external devices. For example, this communication may be used to provide and receive operating parameters, user instructions or notifications, performance characteristics, user preferences, or any other suitable information for improved performance of refrigerator appliance. In addition, it should be appreciated that external communication systemmay be used to transfer data or other information to improve performance of one or more external devices or appliances and/or improve user interaction with such devices.

For example, external communication systempermits controllerof refrigerator applianceto communicate with a separate device external to refrigerator appliance, referred to generally herein as an external device. As described in more detail below, these communications may be facilitated using a wired or wireless connection, such as via a network. In general, external devicemay be any suitable device separate from refrigerator appliancethat is configured to provide and/or receive communications, information, data, or commands from a user. In this regard, external devicemay be, for example, a personal phone, a smartphone, a tablet, a laptop or personal computer, a wearable device, a smart home system, or another mobile or remote device.

In addition, a remote servermay be in communication with refrigerator applianceand/or external devicethrough network. In this regard, for example, remote servermay be a cloud-based server, and is thus located at a distant location, such as in a separate state, country, etc. According to an exemplary embodiment, external devicemay communicate with a remote serverover network, such as the Internet, to transmit/receive data or information, provide user inputs, receive user notifications or instructions, interact with or control refrigerator appliance, etc. In addition, external deviceand remote servermay communicate with refrigerator applianceto communicate similar information.

In general, communication between refrigerator appliance, external device, remote server, and/or other user devices or appliances may be carried using any type of wired or wireless connection and using any suitable type of communication network, non-limiting examples of which are provided below. For example, external devicemay be in direct or indirect communication with refrigerator appliancethrough any suitable wired or wireless communication connections or interfaces, such as network. For example, networkmay include one or more of a local area network (LAN), a wide area network (WAN), a personal area network (PAN), the Internet, a cellular network, any other suitable short- or long-range wireless networks, etc. In addition, communications may be transmitted using any suitable communications devices or protocols, such as via Wi-Fi®, Bluetooth®, Zigbee®, wireless radio, laser, infrared, Ethernet type devices and interfaces, etc. In addition, such communication may use a variety of communication protocols (e.g., TCP/IP, HTTP, SMTP, FTP), encodings or formats (e.g., HTML, XML), and/or protection schemes (e.g., VPN, secure HTTP, SSL).

External communication systemis described herein according to an exemplary embodiment of the present subject matter. However, it should be appreciated that the exemplary functions and configurations of external communication systemprovided herein are used only as examples to facilitate description of aspects of the present subject matter. System configurations may vary, other communication devices may be used to communicate directly or indirectly with one or more associated appliances, other communication protocols and steps may be implemented, etc. These variations and modifications are contemplated as within the scope of the present subject matter.

With additional reference to, an enclosed pan or auxiliary compartment, e.g., illustrated herein as deli panis disposed within the fresh food chamber. In the illustrated embodiment, the deli panis constructed similar to conventional slide-out drawer compartments that are normally provided in a refrigerator's fresh food chamberto support items being stored therein. As explained herein, aspects of the present subject matter are directed to improved methods for regulating the cooling airflow between and among fresh food chamberand deli pan.

According to the illustrated embodiment, fresh food evaporatorcan be housed within an evaporator duct. An evaporator fan, which can be referred to as the first refrigeration fan or a primary fan may be disposed in the fresh food chamber, is used to pass air over the refrigeration evaporatorfor cooling of a fresh food chamber. More specifically, evaporator fanmay be selectively operated to cool fresh food chamber, e.g., by drawing in a flow of primary cooling air (identified generally by reference numeral) through an inlet, cooling the flow in evaporator duct, and passing the flow back into fresh food chamberthrough a primary outlet.

In addition, refrigerator appliancemay include an auxiliary ductthat provides fluid communication between deli panand evaporator ductand/or fresh food chamber. More specifically, according to the illustrated embodiment, auxiliary ductis fluidly coupled to a top end of evaporator duct. In addition, an auxiliary fan, which can be referred to as the second refrigeration fan, is operably coupled to auxiliary ductand is configured to selectively urge a flow of auxiliary air (identified generally by reference numeral) through auxiliary ductand into deli pan.

Now that the construction and configuration of refrigerator appliancehas been presented according to an exemplary embodiment of the present subject matter, an exemplary methodfor operating a refrigerator appliance is provided. Methodcan be used to operate refrigerator applianceor to operate any other refrigeration appliance. In this regard, for example, controllermay be configured for implementing method. However, it should be appreciated that the exemplary methodis discussed herein only to describe exemplary aspects of the present subject matter and is not intended to be limiting.

As shown in, methodincludes, at step, operating an evaporator fan at a first speed to provide a flow of primary air into a chilled chamber. In this regard, continuing the example from above, evaporator fanmay be operated to circulate the flow of primary airthrough inlet, into evaporator ductwhere the air is cooled by evaporator, and back into fresh food chamberthrough outlet. It should be appreciated that the first speed may be determined by controllerbased on the cooling needs of fresh food chamberor may be determined in any other suitable manner. This first speed may also be referred to as the nominal or standard operating speed.

Stepincludes receiving a request to cool the auxiliary compartment. In this regard, controllermay need to periodically circulate cool air into deli panto maintain a desirable temperature therein. Stepmay include operating the auxiliary fan to urge the flow of auxiliary air into the auxiliary compartment. Notably, drawing the flow of auxiliary airinto deli panmay take a portion of the flow of primary airbefore it reaches fresh food chamber. In addition, operation of auxiliary fanmay draw in warm air from fresh food chamberback into evaporator duct, resulting in an undesirable increase in the temperature and/or humidity within deli panand affecting system cooling efficiency.

Accordingly, stepmay include operating the evaporator fan at a second speed, the second speed being higher than the first speed. In this regard, the speed of evaporator fanmay be increased to compensate for the draw of the flow of auxiliary air, e.g., thereby ensuring proper cooling of both fresh food chamberand deli pan. Although example speed adjustments are provided below, it should be appreciated that these speeds are only examples and are not intended to limit the scope of the present subject matter in any manner.

According to example embodiments, the second speed may be a fixed offset relative to the first speed. For example, the fixed offset may be between about 100 and 400 revolutions per minute (RPM) more than the first speed. According to still other embodiments, the second speed may be a predetermined percentage higher than the first speed. For example, the predetermined percentage may be between about 5% and 50%, between about 10% and 30%, or about 20%. According to still other embodiments, the second speed may be a predetermined fixed speed, e.g., as determined by the manufacturer or programmed into controller. For example, the first speed may be between about 1800 and 2200 RPM (e.g., such as 2000 RPM) and the predetermined fixed speed may be between about 2000 and 2400 RPM (e.g., such as 2200 RPM). Other speed variations are possible and within the scope of the present subject matter.

According to example embodiment, it may be desirable to ensure that the evaporator fan is running any time the auxiliary fan is running. Accordingly, stepmay include determining that the evaporator fan is off and stepmay include turning off the auxiliary fan.

depicts an exemplary control method having steps performed in a particular order for purposes of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that the steps of any of the methods discussed herein can be adapted, rearranged, expanded, omitted, or modified in various ways without deviating from the scope of the present disclosure. Moreover, although aspects of the methods are explained using refrigerator applianceas an example, it should be appreciated that these methods may be applied to the operation of any suitable appliance.

As explained herein, aspects of the present subject matter are directed to a method of operating a refrigerator. In general, the refrigerator controls the speed of an evaporator fan for a temperature-controlled pan (e.g., a deli pan) cooling and may include one or more evaporators, a fan for moving air from the evaporator to a compartment, a temperature-controlled pan (deli pan), and an auxiliary fan (deli fan) that moves air from the evaporator to the temperature controlled pan. The method may include running the evaporator fan at a designated/increased speed when the deli fan is ON. The evaporator fan may run at a requested speed when the deli fan is ON, and when the deli fan is OFF the speed of the evaporator fan is not controlled. The logic may request a proportional increase in the current evaporator fan speed instead of a predetermined speed (i.e. a 10% increase in the currently voted speed). For example, if the evaporator fan is running at 2000 RPM (deli fan==OFF), the logic increases the speed to 2000 RPM x 110%=2200 RPM when the deli fan is ON. The evaporator fan may be maintained at variable speed logic as determined by the needs of other portions of the system. Alternatively, the logic may request a flat increase in the current evaporator fan speed instead of a predetermined speed (i.e. 2000 RPM increase in the currently voted speed). If the evaporator fan is running at 2000 RPM (Deli fan==OFF), the logic increases the speed to 2000 RPM+200 RPM=2200 RPM when the deli fan is ON. Therefore, by increasing the evaporator fan speed, the freezer compartment receives the same volume of airflow regardless of the deli fan ON/OFF condition.

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.